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By B. E. Davis, D. A. Stanley, C. E. Jordan

A prototype expert advisor was developed by the U.S. Bureau of Mines to systematically offer advice on the control of a Florida phosphate operation. The PC based system receives input from remote sensors for circuit parameters such as feed rate, reagent addition, and pH and from operator entered information such as the quality of the concentrate and tailings in each of the coarse, fine, and amine flotation circuits. The computer evaluates the information using rules obtained from industry representatives and Bureau flotation experts. Recommended actions and questions are displayed to quickly guide the operator to a problem within the flotation circuit and suggest a solution. This process control system could provide more uniformity among the flotation operators and also serve as a trainer for new operators. In addition, it represents a step toward fully automated systems for phosphate flotation.

Jan 1, 1990

By Richard M. Levine

Now that the former Soviet Union has divided into 15 countries, it is necessary to analyze separately the industrial mineral position of each of these countries. Industrial mineral data The former USSR was one of the world's largest producers of industrial minerals and had some of the world's largest reserves. Production and reserve figures, however, must be qualified. Even when these figures were reported by the Soviets, it was not clear that the production figures were for products that would be equally marketable in a competitive market economy. The reserve figures are based on the Soviet system of reserve classification, which is not directly equatable with the US Geological Survey and US Bureau of Mines classifications of economic reserves in market economy countries. The Soviets reserve classification system, in terms of which reserve figures will be given, is based on the reliability of the quantity of the material in place. The Soviet system assigns each occurrence to one of seven categories A, B, C1 and C2 are considered reserves; P1, P2, and P3 are considered resources. Mining in the former Soviet Union was authorized on the basis of the reserves in place in categories A, B and C, which had to be in prescribed ratios. However, the categories A, B and C do not necessarily correspond to Western concepts of material economically exploitable under present market prices with existing technologies.

Jan 1, 1992

By T. Gouri Charan

Indian coals, which are of Gondwana origin, contain high amounts of mineral matter, wherein the extraneous material was intimately mixed in the coal matrix during the formation stage, causing a high level of impurity in the run-of-mine (ROM) material. These coals possess difficult to very difficult washability characteristics. Beneficiation of high-ash non-coking coals of India has become the prerequisite for improving the overall economics and efficiency of power generation. The use of dry cleaning systems in India for beneficiation of non-coking coals has gaining renewed interest recently. The benefit of the dry beneficiation process is to exploit the given resources while providing a more reliable and consistent quality fuel with a low operating cost. M/S Allmineral has introduced a technique for the dry beneficiation of coal, which is being tried in India for the treatment of high-ash non-coking coals. The first commercial air jig of 50 t/hr capacity was installed and commissioned to beneficiate high-ash coals of 40 x 5 mm feed with an ash content of 40%; a clean coal product of 33% ash was produced and is being used for a sponge iron plant.

Jan 1, 2011

By Melvin E. Poad

INTRODUCTION The placement of concrete by means of pumping is one of the fastest growing practices in the construction industry and is widely used in mining applications. In¬troduced in the United States in 1933, this method has been adapted to many aspects of the industry, especially where space for equipment is either limited or inaccessi¬ble. Concrete pumping offers many advantages over other methods of placement. Using pumping equipment, the concrete mixture can be transported in a single operation from a central mixing site to numerous forms in many remote locations, eliminating the need for rehandling the mixture and reducing the labor costs to a minimum. Pressurized pumping provides an extra mix¬ing and blending step, resulting in concrete of improved uniformity and greater density. In turn, this produces high compressive strength and increased durability. Various placement defects can be reduced or pre¬vented by pumping. The steady and even flow of the concrete minimizes the form distortion and delays caused by vibration problems that are common to fast dumping of the concrete mixes. Segregation, planes of weakness, bleeding, and surface faults are diminished considerably. Perhaps the greatest advantages of concrete pump¬ing are the distances and volumes that can be handled. Depending upon the equipment used, pumping rates of from 8 to 115 m'j/h (10 to 150 cu yd per hr) can be achieved, with a horizontal range of up to 460 m (1500 ft) and a vertical range of up to 140 m (450 ft). Theoretically, almost any concrete mixture could be pumped. However, consistency is an important consid¬eration for efficient operation. Mixes that are too wet, too dry, too hard, or poorly graded can cause difficulties that increase the costs. Similarly, mixes containing aggregate material that is over the maximum size or that is porous and highly absorptive can also result in diffi¬culties and increased costs. For the best efficiency, the mix formulation must have a well-graded sand and aggregate combination, with enough fines to provide flowability. If additional water is required for pumping, additional cement must be used to meet the design criteria of the structure. Each pump manufacturer can provide recommended mix formulations for the specific equipment furnished. Since the 1950s, many improvements have been made in pumping technology. Originally, only rigid steel pipe of 168 to 245 mm (6.625 to 9.625 in.) diam was used; today, both rigid steel pipe and flexible conduit are available in diameters of from 76 to 203 mm (3.0 to 8.0 in.). Improved pumps have been developed, and the introduction of power-coordinated booms has in¬creased the versatility of concrete pumping. The older and more conventional placement methods can no longer compete with the flexibility, efficiency, and econ¬omy of the pumping method, and continued research and development can only improve the system and expand its use throughout the mining industry. PUMPING EQUIPMENT The three major types of concrete pumping units currently available are the piston pumps, the pneumatic pumps, and the squeeze-type pumps. Table I provides a comparison of capacities, horizontal ranges, and vertical ranges for pumps of all three types. Piston Pumps The simplest of all concrete pumps are the piston¬type pumps; they are available from many manufac¬turers. As shown in Fig. 1, each unit consists of a

Jan 1, 1982

By Don Rose

Steel-fiber-reinforced-shotcrete (SFRS) methods of testing and the wording of specifications vary from country to country. In the USA ASTM C1018 is widely used. The Canadians have taken a close look at C1018 and point out that exact determination of the first crack is very subjective, and they propose a method of design that eliminates this variable. The Europeans (EFNARC) have taken the principles of testing a step further than ASTM C1018, and have added a new step in measuring the effectiveness of SFRS. EFNARC uses an "energy absorption" of a plate loaded in its center, in addition to the principles of C1018. The principles of SFRS design are also used in Japan, Norway and elsewhere.

Jan 1, 1999

By William J. Miles

From a historical perspective, bentonite is the common rock term for various uses and applications. Its name originates from water-based muds near Fort Benton used for lubrication of wagon wheels during the 19th century migration to western territories (which are presently part of the United States) when the pioneers ran out of axle grease. From a clay mineralogy perspective, bentonite is composed primarily of montmorillonite, an expandable magnesium aluminum silicate clay mineral. When magnesium occupies an octahedral structural site that usually contains an aluminum atom, a negative charge is created. In order to neutralize negative charges, cations are drawn to the interlayer surfaces between clay mineral sheet structures. Modem applications for bentonite depend on the sodium or calcium cation populations and other characteristics of the clay mineral. When sodium is the dominant cation, the material is called sodium bentonite, also known as swelling bentonite, western bentonite or Wyoming bentonite. When calcium or magnesium is the dominant cation, the material is called calcium bentonite, also known as non-swelling bentonite w southern bentonite.

Jan 1, 2012

By Fred T. Towne

There are a number of air classifiers manufactured throughout the United States and the rest of the world. The classifiers manufactured by Alpine, A. G. of Augsburg, Germany, are unique in their abilities. It is this uniqueness that I wish to delve into and in this respect we will limit this discussion primarily to the classifiers as manufactured by Alpine. It has been reported in the past that these classifiers were introduced into the. United States in the late 50's. Until the introduction of the Alpine Classifiers, air classification seldom produced a satisfactory fractionation of a product below 45 microns (325 mesh) or above approximately 22 mesh. It has been a common practice to classify fine materials which used water as a carrier medium The use of centrifuges are today producing thousands of tons of finely partitive powders in the very small particle size range. The use of centrifuges in connection with wet grinding mills has increased the rates of production of these mills considerably.

Jan 1, 1965

By Irwin R. Higgins, Joseph C. Milbourne

The selection of a suitable nitrate removal process depends on a variety of site-specific chemical and environmental issues. The dominant technologies for nitrate removal include biological denitrification and continuous countercurrent ion exchange. The decision to apply either of these technologies, or both together, depends on the nature of the waste water to be treated. Factors that affect the selection of the biological system include the feed composition and feed temperature. Ion exchange nitrate removal systems ere less sensitive to the feed composition but require disposal or destruction of the concentrated pregnant eluate. The paper discusses Tetra's continuous countercurrent ion exchange technology (CCIX™) and fixed film biological reactor, Denite®. The treatment of the ion exchange pregnant eluant is also discussed.

Jan 1, 1995

By S. S. Nadgauda, A. J. Hathaway

Typically, as long as the coal quality is within the specified range, electric utilities have used delivered cost of fuel per million Btu as the primary criteria for qualified coals when making coal-procurement decisions. Such an approach may not fully address the total cost of using different quality coals at a given plant. A practical and easy-to-build model is described for estimating plant-specific utilization costs for coals of different qualities. Examples are included to illustrate the modeling results for plants operated by two utilities. While the model has certain limitations, it does represent an improved method for evaluating coal bids, and, consequently, reducing generation costs.

Jan 1, 1990

By John Reilly

"INTRODUCTION Successful management of megaprojects, meaning delivery within budget, on time and according to expectations, is a fundamental requirement. Many projects have been successful, some have not. This paper reviews megaprojects1, drawn from the author’s projects over the last 50 years, with “lessons-learned” and a summary of recommendations that, if implemented, would improve megaproject management and delivery. Characteristics of these projects are summarized – including outcomes related to key factors such as politics, management, organizational structure, contracting methods, cost estimates, risk and other elements. The projects include the Washington D.C. Metro, Boston Southwest Corridor, LA Metro, Toronto Rapid Transit Expansion Program, BART San Francisco, MARTA Atlanta, London Underground and the Washington State Highway megaprojects – including the SR520 Floating Bridge and the Alaskan Way tunnel. Other projects that illustrate successful, innovative management and contracting methods include the Madrid Metro (low-cost delivery), the Sydney Northside Storage tunnel (outturn cost, alliancing) and the Lake Mead tunnel (working in partnership, risk management). KEY ISSUES A characteristic of megaprojects is that their complexity increases exponentially with size (Reilly 2010, Galloway et al. 2012). These projects are very visible politically, have many stakeholders who must be satisfied and generally span many years and political election cycles. To be successful they must meet expectations, function efficiently, and be delivered under, at or close to budget and schedule. There is a widely-based perception that large, complex projects are always delivered late, over budget and with problems. Specific examples include projects such as Tren Urbano in Puerto Rico – $1.28 billion over initial budget (+133%), the Silver Line Transitway Project in Boston – $286 million over budget (+90%), the London Jubilee Line Transit Project – 2 years late and £1.4 billion (+67%) over budget, the Channel Tunnel Rail Project – £3.7 billion (+80%) over budget, Denmark’s Great Belt Link rail and road link (54% over budget), the 2003 Woodrow Wilson bridge tender in Virginia (72% over estimate) and Boston’s Central Artery Project – several billion (perhaps 100%) over what would have been a realistic initial budget and years late (Reilly 2001c, 2004a; Salvucci 2003)."

Jan 1, 2016

By J. J. K. Daemen, C. Fairhurst

Two aspects of tunnel support design are considered, and for both particular attention is paid to the influence of rock failure around the tunnel on the loads developed on the supports. 1) In general it has not been possible to extend analytical methods for the study of rock failure around tunnels to three dimensions. As a consequence it was not possible to calculate either the influence of the face or the actual sequence of support loading as the face advanced. The finite element method made this extension possible. A simplified analysis of the influence of the face and of the sequence of support installation has been made. The influence of the original stress field and of the rock behaviour on the length of tunnel which can be left unsupported (related to the stand-up time) is shown. The degree to which a 2-dimensional analysis can be used to approximate the final support load is shown to be dependent upon the post-failure behaviour of the rock. 2) Tunnel support design requires a knowledge of the forces and of the -rock displacements which cause stressing and deformation of the support system. A 2-dimensional model incorporating a detailed representation of several support systems, of the rock behaviour in the broken zone and of the interaction between rock and support is given. The model allows the calculation of the stress distribution in the support. The significance of the relative stiffness of support and rock on the stresses developed in the support is shown.

Jan 1, 1997

By John E. Litz

Since the 1974 introduction of catalytic converters to automobiles in the United States, more than 150,000 kg (5,000,000 oz) of platinum, palladium, and rhodium have been used in the converters. An estimated 8 to 10 million converters are being used annually in the United States, each containing from $5 to $15 of PGM metals. In addition, use of converters is beginning in Europe which will significantly increase the quantity of PGM used. Two basic types of catalysts for converters are being used: pellet and monolithic. The pellets are small, discrete spheres or cylinders of gamma-alumina coated with platinum group metals, Figure 1. The monolithic are honeycombs of a cordierite, A13(Mg,Fe)2Si5AlO18, base coated with gamma-alumina and subsequently with platinum group metals, Figure 2. Pellet catalysts are being used by General Motors and American Motors; whereas Ford and Chrysler are using monolithic catalysts. The table below compares the PGM content and value of the catalysts.

Jan 1, 1986

By M. Misra

The dispersion of oily collector has significant effect on the flotation recovery of ultrafine coal. Generally, reagent dispersion is accomplished by mechanical mixing and/or ultrasonic agitation, followed by direct addition of dispersed collector into the flotation cell. However, such dispersion and reagent addition techniques are invariably inadequate and non-selective. A new collector utilization technique involving gas phase transport of atomized collector has shown improved results when compared to conventional reagent addition techniques. This new technique involves atomization of the collector into the gas stream. Under these circumstances an aerosol is introduced into the flotation cell. Initially, the oil is dispersed within the gas phase (continuous with respect to oil) and the gas phase is dispersed within the pulp (continuous with respect to aerosol). In the flotation cell, the atomized oil droplets coalesce on the bubble's surface and create a de-facto oil-encapsulated bubble. This approach provides excellent dispersion, increases selectivity, and most significantly increases the flotation rate of ultrafine coal. Furthermore, atomization of collector/frother combinations yielded improved flotation yields and maintained near uniform froth levels which is a desirable feature in coal flotation. In addition to flotation experiments, microscopic examinations of the attachment of oil-coated bubbles at a coal surface were conducted by attachment-time and contact-angle measurements. The oil coated bubbles attach at significantly faster rates and with a higher contact angle than do oil free bubbles.

Jan 1, 1987

By D. M. Conner

An innovative patented process has been developed to convert high volume wastes--fly ash from coal-fired power plants, municipal solid waste (MSW) ash from incineration, solids from waste water treatment and paper mill sludge into a high value and environmentally benign product in the form of a lightweight aggregate. Lightweight Aggregate is widely used in the building construction industry in the United States, Europe and some Asian countries. This paper will present the development of the process, the process itself and details on the first commercial scale plant. The commercial plant is owned and operated by Wisconsin Electric Power (WEPCO).

Jan 1, 1997

By Paul Mitchell, Clive Potter, Miles Watkins

Meldon Quarry is a seemingly rare occurrence of acid rock drainage (ARD) in a quarrying operation.4 With surface waters discharging to a tributary of a salmon-bearing river, it is subject to stringent discharge conditions. The quarry predates effective environmental management, and preventative, control and treatment measures were not implemented until relatively recently. However, retrospectively implementing standard preventative approaches at the site is costly, technically difficult and of uncertain benefit. This paper overviews the recent site history and introduces data from a demonstration by KEECO (UK) Limited of its Silica Micro Encapsulation (SME) water treatment technology.

Jan 1, 2000

By M. D. Bath

Minproc Engineers Inc. (Minproc) recently completed the construction and start-up of a process facility to treat 14,000 t/d of gold-silver ore at Kori Kollo, Bolivia. The comminution circuit consists of crushing and SAG-ball mill grinding. Breakage characteristics of the ore were determined and a circuit model developed. This enabled variations of the circuit to be simulated, and evaluated in terms of predicted performance to provide the criteria for final engineering design. Subsequently, analysis of the operating circuit provided data for circuit model-fitting. The validity of the original model and circuit performance predictions are discussed.

Jan 1, 1994

By Donald W. Trepp

Colony Development Operation is a joint venture currently consisting of four active members; The Oil Shale Corporation (TOSCO); Ashland Oil Inc.; Shell Oil Company and Atlantic Richfield Company, operator of the project. The initial efforts on the Colony project began in the spring of 1965. Pilot mining and semi-works engineering programs continued, in phases, to completion in the fall of 1972 when commercialization of oil shale was deemed realistic. Since that time, Colony efforts have been directed toward evaluation of the data collected during the semi-works operation and in designing a commercial operation. In October of 1974, Colony announced: "because of economic and national energy policy uncertainties it was suspending plans to start construction of a commercial oil shale plant on private lands in northwestern Colorado, scheduled for spring of 1975."

Jan 1, 1975

By Earl Cook

A high-energy economy based on fossil fuels is in fundamental conflict with an ideal of clean air, clean water, undisturbed scenery, and maintenance of fragile ecosystems. There is an inevitable trade-off between the material standard of living of a modern society and the conservation of its environment. During the past four years, some of the costs of environmental protection have been internalized in the energy-flow system of the United States. The cost of bituminous coal and fuel oil usable under new air-quality standards has doubled or more. The cost of mining coal underground has risen because of a 20-30 percent reduction in productivity resulting from new environmental health and safety legislation; the economic impact of proposed surface-mine regulation may be equally severe. The cost of producing electric power has been rising at a 12 percent annual rate because of environmental costs, and would be climbing still more steeply were it not for the continued forced subsidy of natural-gas consumers by natural-gas producers. The efficiency of the automobile, already a monument to the triumph of self- indulgence over economy, is being further decreased by addition of anti-pollution devices. Part of the recent sharp rise in agricultural costs stems from the fact that five energy units of fossil fuel go into U.S. agriculture for every energy unit of raw food that leaves the farm; further large injections of fossil-fuel energy occur in the transport, processing, and refrigeration of farm products.

Jan 1, 1974

By James A. Brierley

The author has known Professor Wadsworth since the 1960s, when interest in the application of microbial technology for metallurgical processes was beginning its rapid rise. The development of bioleaching and mineral biooxidation was advanced, in part, by Wadsworth's belief in the potential for its application, as well as by his numerous contributions to the understanding of the fundamentals of hydro-metallurgy. Wadsworth is recognized for fostering research and development of the field and adding credibility to microbiological-based metallurgical processes, now often referred to as biohydrometallurgy. This Wadsworth Award is recognition of the field of biohy-drometallurgy. It is an honor to serve as a representative for all those individuals involved in research and commercial development of this technology. Modern commercial application of biohydromctallurgy began with the bioleaching of copper from submarginal-grade. run-of-mine material. Kennecott Copper successfully developed this process in the 1950s at the Bingham Canyon Mine in Utah. Other mining operations around the world followed Kennecott's lead. Today, dump bioleaching remains a very low-cost process for scavenging copper from rock that cannot be economically processed by any other method. Despite the commercial success of dump bioleaching, little effort has been made to enhance the micro Biological component of this leach process. Expansion of biohydro metallurgy into recovery of other metals did not occur until the mid-1980s, when the first commercial plant for the pretreatment of refractory gold-bearing concentrate was commissioned at the Fairview operation in south Africa. Now, processes for copper bioleaching and refractory gold pretreatment are engineered specifically to promote the activity of the microorganisms. This paper reviews the current state of commercial applications of biohydrometallurgy. It examines potential future developments and portrays the role of the microbiologist in facilitating continued growth and commercial acceptance of the technology. The commercia1 examples in this paper illustrate the expansion of microbial processing in the mining industry during the last 20 years. Copper bioleaching Early commercial applications of bioleach technology involved processing submarginal-grade, copper- bearing, run-of- mine rock in dumps. Recent applications of the technology use engineered bioleach heaps. Currently. all of these operations are in the Southern Hemi-

Jan 1, 2000

By R. A. Matuszak

U.S. Government sponsored studies proclaim large reductions in surface mine productivity. Consulting studies place a large share of the blame on increased governmental regulatory activities and on inexperienced, improperly train people. Union rules, which allow indescriminate bidding for job openings, seem to be a major factor causing the lack of experience in spite of elaborate training programs.

Jan 1, 1982