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By H. Fayed

Froth flotation technology is the backbone of the minerals pro-cessing industry where minerals are concentrated by selective separa-tion; either direct or in-direct flotation. In direct flotation useful minerals are conditioned to become hydrophobic (water-repellant) and attach to air bubbles while impurities (non-useful particles) remain in water. The hydrophobic particles are transported by air-bubbles to the top froth (foam) layer in flotation tank which can be removed as a concentrate. There are many factors that controls this selective separation process such as: particle’s degree of hydrophobicity, size, mass loading, air holdup and bubble size distribution. Turbulent fluctuation of the slurry in the tank is another important factor that controls the collisions rate between particles and bubbles and hence attachment rates. The turbu-lent fluctuations are measured by the local distribution of turbulent dissipation rates. Conventional flotation machines are restrained by residence time of the slurry that is about 3-5 minutes that results in a large footprint and limits the capacity of flotation plants. The designers of conventional flotation machines try to reduce the footprint of flota-tion tank by scaling up the flotation machines to increase plant throughput. The scale-up process reduces the specif power consump-tion and the local distribution of shear rates and turbulence dissipation rates. This scale-up results in a larger mean bubble size and lower particle-bubble attachment rates.

Feb 1, 2023

By Liming Yuan, Wei Tang, RICHARD THOMAS, JOHN SOLES, DAVOOD BAHRAMI

Mine equipment fires remain as one of the most concerning safety issues in the mining industry, and most equipment fires were caused by hot surface ignitions. Detailed experimental investigations were conducted at the National Institute for Occupational Safety and Health’s (NIOSH) Pittsburgh Mining Research Division on hot surface ignition of liquid fuels under ventilation in a mining environment. Three types of metal surface materials (stainless steel, cast iron and carbon steel), three types of liquids (diesel fuel, hydraulic fluid and engine oil) and four air ventilation speeds (0, 0.5, 1.5 and 3 m/s) were used to study the hot surface ignition probability under these conditions. Visual observation and thermocouples attached on the metal surface were used to indicate the hot surface ignition from the measured temperatures. Results show that the type of metal has a noticeable effect on the hot surface ignition, while ventilation speed has a mixed influence on ignition. Different types of liquid fuels also show different ranges of ignition temperatures. Results from this work can be used to help understand equipment mine fires and develop mitigation strategies.

Oct 1, 2022

By HONGWEI YANG, Lili Zhang

Copper slag is mainly used in cutting tools, abrasives, asphalt pavement, road construction, and in the production of concrete as an alternative to sand and cement [1]. As a renewable resource, only about 15-20 percent of the slag is used for these applications, and the dumping or disposal of surplus unused slag results in waste of a certain amount of usable metal in the feedstock [2]. In this work, the oxidation behavior of copper smelting slag under nonisothermal condition is studied using data obtained by the thermogravimetric (TG) method, and the kinetics parameters and reaction mechanism of oxidation are determined. It provides a theoretical basis for the comprehensive recovery of iron resources in slag and the selection of reasonable slag-making conditions.

Oct 1, 2022

By STEVEN J. SCHATZEL, Zoheir Khademian, KAYODE M. AJAYI

The integrity of unconventional shale gas well casings positioned in the abutment pillar of a longwall mine could be jeopardized by longwall-induced deformations. Under such scenarios, the surrounding fracture networks could provide pathways for gas flow into the mine, creating safety concerns. To provide recommendations for developing guidelines that ensure a safe coexistence of longwall mining and unconventional shale gas production, this study uses a discrete fracture network (DFN) model to evaluate the impact of parameters that could affect potential shale gas flow into the mine in the event of a casing breach. These parameters are evaluated using a conceptualized DFN realization that is representative of the fractured zone in the overburden, and the range of parameter variations are within values validated with field measurements.

Mar 1, 2023

By A. Juganda, F. WILSON, G.E. BOGIN, H. PINHEIRO, N. SANDOVAL, J.F. BRUNE

To evaluate methane explosion hazards in underground longwall coal mines, researchers at the Colorado School of Mines developed a computational fluid dynamics (CFD) model along with a 1/40th-scale, optically accessible, physical model of a longwall mining section. In this project, CFD models assisted in the design of the physical model to ensure specifications were met to accurately represent the scaling physics as well as to assist in narrowing the experimental matrix and identifying key locations for sensor placement to measure velocity, pressure and gas concentrations. This research will help develop strategies for methane monitoring to prevent methane ignitions and explosions in longwall coal operations.

Dec 1, 2022

By Timothy Batchler, Khaled Mohamed

Standing supports have been used in coal mines for decades to enhance roof support capability. Occasionally, standing supports are used to resist the lateral movement of spalled ribs. Researchers from the National Institute for Occupational Safety and Health (NIOSH) are conducting a testing program for standing supports to investigate the effect of lateral loading on their vertical loading capacities and the factors affecting their lateral loading capacities. The Mine Roof Simulator (MRS) was used to determine the response of steel props to vertical and horizontal loadings. Finite element models (FEMs) were developed and verified using the tested steel props. Prop models were used to study the effect of a range of roof and floor materials — gray shale, shale and claystone — on the critical buckling loads of the steel props.

Dec 1, 2022

By MYRIAM FRANCOEUR, JOHN R.R. BOWLING, ADAM MCFADDEN

As duct-fan systems push the envelope of power, length and cost, their design calls for a more comprehensive technoeconomic analysis to ensure they deliver the expected results without failure and cost overrun. This work explores the numerous factors to include in the design of an extensive (semi-)rigid duct-fan system. Besides delivering a given airflow, the system must satisfy component limitations and power constraints during its lifetime. We evaluate the assumptions underlying the positioning of in-line booster fans in a long gapless duct-fan system and propose a strategy for specifying the location and blade pitch of successive booster fans to prevent system failure due to a partial vacuum.

Oct 1, 2022

By Y. Pan, P. Tukkaraja, R. BHARGAVA, V.V.S. VYTLA, S.J. SRIDHARAN

Panel caving is an underground bulk mining method that uses gravitational force to mine massive, steeply dipping and deep-seated ore deposits at lower operating cost. To control dust and gas emissions entering the production level during the extraction of ore from the draw points in a panel cave, relatively negative pressure is created in the cave by installing an exhaust fan in the exhaust drift located on top of the cave. As caving is a dynamic process, designing an effective ventilation system is challenging; therefore, estimating the airflow resistance offered by the broken rock inside the cave is critical. This study investigates the effect of changes in the bulk porosity of the broken rock on the cave airflow resistance using the computational fluid dynamics (CFD) approach. The results show an inverse relationship between the cave airflow resistance and the bulk cave porosity. The pressure-quantity characteristic curves presented in this paper provide valuable information for sizing and operating an exhaust fan used for a mature panel cave ventilation.

Nov 1, 2022

By E. Watkins, S. J. SCHATZEL, K M. AJAYI, V. Gangrade, Z. Khademian

A stochastic discrete fracture network (DFN) model is developed based on mine site core log data to predict the horizontal and vertical permeabilities from the surface to the top of the caved zone at a longwall mining site in southwestern Pennsylvania. One hundred DFN realizations were generated to determine permeabilities for the isolated zone over an abutment pillar after mining the second panel. The results from this study show that the vertical and horizontal permeabilities from the DFN model agree closely with field measurements, which indicates that the resultant permeability obtained from the field measurements is representative of the predicted permeabilities. With this agreement, the aperture data for other zones of the mine could be obtained from the geomechanical model — specifically, for the fractured zone over the gob. Based on the successful validation of this model, this model could be further developed to predict the permeability of the fractured zone over the gob with fracture aperture obtained from the geomechanical analysis. This will complete the fracture characterization of the overburden, which could be used to predict potential shale gas flow to the mine in the event of a breach. This prediction could provide information on the associated risk of a casing breach and determination of methods to proactively prevent such an occurrence.

Feb 1, 2023

By R. H. King

Recently, the North American mining industry experienced a severe recession, forcing managers to take dramatic steps to cut costs and compete in the difficult international market. Some of these steps were closing mines, reducing work forces, renegotiating wage agreements, and purchasing the most productive equipment. Managers are now looking beyond these traditional avenues and are focusing more on advanced technology. In the present environment, it is essential that mine operators obtain the maximum use of capital expended on equipment. However, mine workers do not obtain maximum efficiency or productivity from equipment because the adverse and hazardous mine environment impedes human performance. Also, the efficient use of large, complex machines calls for levels of precision that many times are beyond the capability of even highly trained miners. A possible solution to this problem is a machine that mines without operators - autonomous mining machines. However, numerous problems confront researchers who are attempting to develop such equipment. Some mining tasks are not always composed of a series of cyclic motions readily performed by factory floor robots. In addition, mining takes place in the geological environment where conditions are highly variable and unpredictable. As a result, these machines must be able to sense and adapt to variations in operating tasks and environment. Considerable autonomous vehicle research has been completed, especially for defense. However, autonomous vehicle (AV) technology has not advanced to practical application yet (King, 1988) and mining research is necessary in areas: representing mining specific knowledge; •analyzing and reasoning about sensor data in the mining environment; and •discovering completely new mining methods or new approaches to existing methods that become apparent when we remove the constraints imposed by the necessity of human operators. A specific machine, the LHD, can be used to show the problems for researchers who are attempting to develop autonomous machines for mining. This author chose the LHD because it can borrow concepts developed for autonomous navigation by military programs. But considerable mining research is also required. Furthermore, studies done at the Henderson mine, in Colorado, show autonomous LHD 's promise cost and safety benefits (King, 1988). At Henderson, LHDs load ore from draw points, tram to an ore pass, dump and return, or switch to another draw point. An autonomous LHD must sense vehicle position along the route, relate sensor data to stored-map information, to determine location, follow drift center lines, plan paths between dump position and initiate appropriate control commands, sense vehicle operating status and vehicle health, key on features or targets for special tasks like high speed turns, perform end of travel tasks (loading and dumping), and detect and avoid obstacles. These goals are similar to those for shuttle cars, trucks, and front-end loaders. Therefore, much of the technology is transferable. Each Henderson LHD extracts six to 40 dippers from each of a series of draw points. The LHD transports the ore to an ore pass within 55 m (180 ft) of the draw point, making the longest round trip 110 m (360 ft). The LHDs have very fast hydraulic dumping and loading systems that reduce the round trip cycle to less than one minute. Even though the LHD is capable of 500 trips per shift, the average production is 300 dippers. Man trip and lunch reduce available operating time to 6.5 hours per shift. Mucking difficulties (setting large boulders aside), operator breaks for activities like talking shop, and cleaning and smoothing roads further reduce operating time. Supervised autonomy can reduce the number of operating units by increasing operating time per shift since computer controlled machines can operate during lunch and between shifts and reduce operator errors. If dippers per shift increase from 300 to 350 (long-range goals are 500 dippers per shift), constant production requires only 10 operating LHDs and two spares. Manpower requirements drop from 24 to four by controlling five machines from one workstation. A review of technology available from the Autonomous Land Vehicle, the Advanced Ground Vehicle Technology, the Ground Surveillance Robot, and other programs, show the following differences between others work and mining industry needs: •If we focus initially on mobile haulage vehicles, we can navigate from a map. We do not need to explore. •We can modify the environment to reduce the navigation requirements. •We have a harsher environment than any of the research programs have encountered. •Our equipment must operate faster and more precisely than present AVs. •Our equipment must operate reliably over long periods of time. •We must have better onboard machine health monitoring and diagnostics. •The AV programs do not address geosensing. •The major AV programs are not cost-effective. For example, we cannot afford the computer power for robust image processing, yet. To computer control an LHD, we must replace the guidance and monitoring skills of experienced operators with sensors, computing hardware, interfaces, and several software mod¬ules. Experienced operators avoid collisions and load efficiently in piles that may contain oversize muck. Collision avoidance without an operator requires sensing all obstacles in the draw

Jan 1, 1991

By B. Ollila, L. Brown

As mining fronts converge in sill pillar extraction, the mine seismic hazard can be significantly altered and large seismic events have been known to occur. This study used common seismological tools to analyze the extraction of highly stressed sills from two deep Canadian mines with the objective of characterizing the rock mass failure process and relation to large seismic events. The approach treated a sill pillar as a mine-scale failure process, meaning the temporal and spatial analysis scales needed to exist on a similar scale to a significant part of the mine. The temporal analysis scale overlapped with the entire mining sequence, included several years of data to establish long term change in the characteristics of rock mass failure. The spatial analysis scale included the rock mass surrounding a large part of the convergent mining sequence. To accommodate the large spatial and temporal scales, the highest magnitude 2% of events in the dataset were analyzed. Similar results were shown for sill pillars in both mines. Changes in event location, time, magnitude, energy index and apparent volume were similar to expected behavior of rock failure. Indications of strain hardening and strain softening were observed in the sills. The hardening period was characterized by a high rate of small events, high energy index and low apparent volume, giving an indication of high stress and low rock yield. The softening phase was characterized by a decrease in the rate of small events concurrent with an increase in the rate of large events, low energy index and high apparent volume, indicative of release of stress and increase in deformation. Large magnitude seismicity was strongly related to the softening phase, with several Nuttli magnitude 3.0+ events occurring shortly after the transition from hardening to softening failure regimes. Sill failure was indicated by consistently low EI and low levels of seismicity and seismic hazard in the sill pillar.

Apr 26, 2022

By Luis Fernandez-Deza, Kaveh Talebi, Seth Pollak, Soto Vardakos

INTRO PAGE

Jun 13, 2021

By JIACHENG XIE, XUEWEN WANG, QINGBAO BAO, ZEWEN YAN

The general application of memory cutting technology to shearers is improving the intelligence of the working face, but it has its limitations. It is only suitable for conditions where the environment of coal seam is changing slowly. It compensates for the cutting height by changing the fuselage attitude, and frequently adjusts the height to control the learning cutting trajectory, but due to the problems of shearer control and height adjustment accuracy, it cannot adapt to and compensate for the change of cutting height in a timely manner, resulting in poor cutting accuracy. This study puts forward a virtual memory cutting method based on prediction of the shape of the armored face conveyor (AFC). The integrated key technologies include generation of virtual teaching cutting curve, height adjustment strategy of front and rear drums, cutting

By Sebastian Sucri, Percy Townsend

INTRO PAGE

Jun 13, 2021

By Mike Stolkin, Julio Martinez

INTRO PAGE

Jun 13, 2021

By Chris Lynagh, Lisa Smiley

INTRO PAGE

Jun 13, 2021

By Wolfgang Baum

The objective of this presentation is to demonstrate the utilization of process mineralogy to improve the plant performance of a large gold-silver operation. From raw ore to tailings, from concentrate to off-gases, nearly all aspects of the recovery process have benefited from the mineralogical work. The involvement of a process-oriented mineralogist on a routine basis permitted the plant to "unlock" the reasons for process problems and to take corrective measures such as adjusting and modifying the mill circuit and the process parameters. Process mineralogy has also been of substantial value for the selection and operation of equipment. This resulted in a more cost-effective operation with improved precious metals recovery and better by-product quality. Specific modifications made in recent years are largely related to mineralogical factors, particularly the inherent precious metals mineralogy and alteration characteristics of the ore.

Jan 1, 1998

By Peter Erlynne

Rising costs have affected the cost of operating and install­ing crushing circuits, just as they have affected every other area and there is little possibility that the cost cycle is about to be reversed - power costs, wear materials costs and labour costs continue to increase but a basically stable gold price makes little allowance for these cost increases. Additionally, lower grades of ores being worked, and harder feed materials have a significant effect on the potential for higher processing costs. There are, of course, options for size reduction - some of them newer than others - some are suitable for certain types of ores and less suitable for others and it can sometimes be difficult to ascertain the accuracy of anticipated results before plant design and con­struction are completed - by which time the capital outlayed will preclude a change to another method ofreduction. Nordberg's patented WaterFlush Technology has the potential to change the way that Ball Mill Feed production is viewed: Some of the elements that must be considered are: • Capital Cost • Operating Cost • Efficiency • Flexibility • Availability • Control • Support Efficiency • Expertise • Spares availability • Environmental considerations

Jan 1, 1995

By Kevin Bell

The TRAC™ Program was developed to provide our clients with a mechanism that allows them to better manage site remedia­tion and closure costs. This program provides a fixed-price contract for site remediation and case closure and is well suited for large pro­jects with multiple PRPs, such as Superfund sites. Because Kvaerner is a large engineering/construction firm and not a consult­ing firm, we can offer this type of contracting mechanism that envi­ronmental consulting firms are hesitant or unable to provide. With TRAC™, Kvaerner assumes financial and technical responsibilities for carrying a site through the closure process for a fixed price. Liabilities carried on our client's balance sheet for site closure can be removed when they sign up forTRAC™. In many instances, a profit can be realized as the liability on the balance sheet may exceed our TRAC™ fixed-price cost to close the site. Bonds and other sureties securing the site can be released and set­tlement with other involved parties can be quickly reached. For a project to be considered for this program, it typically meets the following criteria: 1) The project site should be physically separated from other contaminated sites 2) A reasonable quantity of site investigation data must be avail­able including site-usage history with or without a projected fea­sibility study(ies) and/or remediation design 3) Access to perform all necessary work must be available. After a review of all site data, K vaerner develops a "risk menu" to manage financial risks. In this "menu", each compo­nent of the project is assigned a level of probability that the costs will occur. Then the base cost of each activity is "weighted" by multiplying the potential cost growth by the probability. This analysis assures that the financial risks are appropriately defined, weighted, and mitigated and a realistic fixed price is developed. Upon acceptance of our proposal and conclusion of contract negotiations, Kvaerner takes over future responsibility for clos­ing your site. This allows the client to: 4) Release reserves obligated on financial statements for the site (and potentially realize a profit if the TRAC™ fixed-price cost is less than our client's booked obligation) 5) Finalize cost settlement with other responsible parties, insur­ers, etc. 6) Redirect resources involved in the environmental manage­ment of the site 7) Cap legal and administrative costs In addition to performing the site cleanup and closure work, at our client's request we are able to: 8) conclude lease obligations for property 9) dispose of equipment and buildings

Jan 1, 1998

By Leslie M. Burnside, Gene E. McClelland, Roy R. Cellan

Revegetation of neutralized heap leach material in the arid environment of the Great Basin represents a challenge of avail­able technology. The chemical and physical environment of spent and neutralized ore is inhospitable for germination and establishment of desirable long term vegetation. Common soil amendments were tested to dete1mine if the heap material could be made more conducive to plant growth. Decommissioned heap material profile samples were collected and reconstructed in columns at bench scale. The column profiles were amended and subjected to three leaching regimes, and representative meteoric conditions. The soil amendments provided positive results for ameliorating the heap material limitations and providing a medi­um conducive to plant growth. The bench scale study also pro­vided insight for the future of heap leach planning and design with successful reclamation in mind at the forefront.

Jan 1, 1998