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By E. Watkins, S. J. Schatzel, V. Gangrade, R. Kimutis, J. Addis, C. Hollerich

The recent shale gas revolution in the United States has led to the drilling of hundreds of unconventional shale gas wells in active and future coal reserves in traditional coal-mining regions of Pennsylvania, West Virginia, and Ohio. This paper summarizes the impact of a shale gas well breach on the mine ventilation system of an operating longwall panel. This study utilizes a 1:30 scaled Longwall Instrumented Aerodynamic Model (LIAM) to simulate a single-panel longwall operation. The LIAM will be utilized to identify flow pathways and distribution patterns of gas from breached gas well scenarios in an operating longwall in the Pittsburgh Coal Seam. Sulfur hexafluoride (SF6) tracer gas is utilized to simulate a breached gas well. Preliminary findings suggest that the breached gas is diluted to regulatory levels and does not accumulate in the mine entries or in the longwall gob when the longwall panel is adequately ventilated. Overall, this study characterizes the potential interaction between shale gas wells and the mine environment in the event of a gas well breach, which provides critical information to the industry and regulatory agencies for improving safety, health, and welfare of miners.

Mar 2, 2022

By J. D. Decker, T. E. Norman

Introduction Grinding is the reduction of ore and similar raw materials to particle sizes below the practical limits of commercial crushing ma¬chines. This size is about 36 in. (1 cm), in most cases, although some finer crushing machines are in regular use. The feed size to grinding machines may range upward to S in. in rod mills, and 12 in. or more in autogenous mills. The finest particle sizes produced in mineral processing operations result from grinding. Ordinary grinding of brittle materials is the result of impacting, rolling, and abrasion of heavy bodies, moving freely under the influ¬ence of gravity. These falling and rolling grinding bodies, which are usually of metal, must be much heavier and larger than the ore parti¬cles they break. This weight relationship is usually in excess of 100: 1. The sustained fall of the grinding bodies is obtained by placing them, together with the rock particles they grind, in a rotating drum or cylinder with horizontal axis, called a tumbling mill. The mill is nearly half full of grinding bodies and ore particles, which may be fed into one end and exit from the other through hollow trunnions which usually serve as the mill bearings. The mill lining must be thick to absorb wear and rough to prevent excessive slippage of the charge. The breakage of brittle rock or ore is accomplished by compression. The compression may be a rapid impact, from the fall and roll of a grinding ball, or it may result from the relatively slow and constrained motion as in a jaw crusher. Breakage by shear is a secondary result of the compressive motion. Ordinary rock has an extremely heterogenous structure with innumerable zones of weakness in which cracks, fractures, and breakages can form. When a rock is subjected to com¬pression it deforms. If the compressive force exceeds a certain critical value an incipient crack appears in the most fragile zones of weakness. This crack tip may first form on the particle surface or in its interior. When the first crack tip forms the compressive stresses immediately surrounding it flow to it, and this concentration of forces extends the crack and splits the rock. Other adjacent cracks may form during this extremely rapid process. Because of the nature of brittle particles, the work done in breaking them consists essentially of the work input required to compress them to the point at which the first crack tip forms. Breakage requires no appreciable additional energy input be¬yond that required for the deformation, since the stress energy already imported to the rock flows to the crack tip and extends it to breakage. Types of Tumbling Mills The general term tumbling mill includes the rod mill, ball mill, pebble mill, autogenous mill, and tube mill. It is of cylindrical or cylindro-conical shape and rotates about its horizontal axis. Rotational speed, liner type, and size and shape of tumbling media are selected to provide the desired operating conditions for the specific grinding application. Openings are provided through the mill ends for feed and discharge of the material being ground. A common feature of tumbling mills is the use of tumbling media

Jan 1, 1985

By Walter C. Labys

This paper reports on recent modeling efforts to analyze the eastern U.S. steam coal market with a cross-sectional econometric as well as a quadratic programming approach. The background to coal modeling is examined first. The particular aspect of the steam coal market to be modeled are then presented and the corresponding coal model described. Both empirical results and rigorous mathematic pertubation analysis are presented. Conclusions are then drawn regarding potential modeling applications in the policy area.

Jan 1, 1979

By John S. Wakeman

The progress results of a pilot plant study on the effects of ball top size and other mill operating parameters are reported. Test series on taconite and quartzite crude ores using a 1.7m diameter primary mill in closed circuit with a vibrating screen indicate clear trends on the improvements of mill throughput and power consumption when using larger diameter balls. Possible effects on mill liner and ball consumption as well as future research plans are discussed.

Jan 1, 1984

By Otto E. Zwanzig

You may think long before this talk has been completed that the speaker is belaboring the obvious. Please let me put to rest here and now any doubt which you may have in this regard by assuring you that is precisely my intent, and for a very specific reason. We all profess to know and recognize the obvious, but I am impressed increasingly how often we forget or fail to act upon the obvious. Shortly after starting my first job upon graduation from college, I was asked by my boss to participate in a course on practical communications, particularly as applied to conveying proposals effectively to the client -- be he customer or company president. The concept or philosophy underlying this program was so simple and obvious that in my youthful brashness I saw only a gross waste by the company of e good, solid $1930 in compelling me to take the course. The sequel to this experience occurred about five yews ago when I was directing a 300-man marketing group. At that time I enrolled a dozen of my department heads, and subsequently about a hundred other personnel, in the contemporary version of that sane program. Why? -- because they all knew the obvious, but I could see how imperfectly they were implementing it. Truly, a wide chasm exists all too often in our beliefs on the one hand and our practices on the other.

Jan 1, 1962

By R. D. Hansen

This paper discusses the influence of frother type and dosage on recovery/selectivity in coal/sulfide mineral flotation as a function of particle size. It is shown that different frother structures do exhibit quite different but consistent performance characteristics depending on the underlying particle size ranges involved as well as the dosage levels of both the frother and collector. The data presented on existing commercial frothers end some new special purpose experimental frothers is used to illustrate some general operator guidelines on proper frother selection and use.

Jan 1, 1985

By J. B. Platt

Many utility fuel choices 1990-95 defied expectations, with utility decisions and coal market developments ever more closely linked. The Central Appalachian coal boom never occurred; clean-enough coal was developed in the hard-hit Midwest; Colorado-Utah coal surged; Pittsburgh seam production strengthened; utilities embraced Powder River Basin coal; and emission allowance prices collapsed. Competition drove productivity gains, but the future is not a simple repeat. Phase 2 brings fewer viable compliance options. Mega-railroad pricing has become a key risk factor --will this be countermanded by merging utilities and power market competition? Revenue losses from vintage contracts are problematic. Uncertainty also plagues natural gas, in spite of unanimity across major forecasts, since recent experience has been so heavily influenced by the gas bubble.

Jan 1, 1997

By C. E. Chapin

The Hansen orebody is a large (1 2 million kg U3O8, 0.08% U3O8 average grade) sandstone-type uranium deposit in the Eocene Echo Park Formation of central Colorado. The deposit occurs in carbonaceous braided-stream sandstones that are part of a wet-alluvial-fan complex that prograded eastward across a narrow strike-slip basin. The Echo Park basin is one of a series of basins that formed along the east side of the Colorado Plateau as it was translated northward during the Eocene culmination of the Laramide orogeny. The valleys of east- and southeast- flowing perennial streams, whose courses were transected by the subsiding Echo Park basin, were filled with permeable volcanic and sedimentary rocks during construction of the Oligocene Thirtynine Mile volcanic field. These paleovalleys funneled large volumes of uranium-bearing ground waters through the braided-stream facies of the wet alluvial fan. Uplift of a basement horst downfan from the Hansen orebody reduced transmissivity and helped maintain a reducing environment in the Hansen area; this later became an important factor in preservation of the Hansen orebody. The horst also deflected uranium- bearing ground waters upward into the Oligocene Tallahassee Creek Conglomerate where they formed the Picnic Tree orebody (1.1 million kg U3O8, 0.09% U3O8 average grade) in an altered ash-fall tuff that is essentially barren above the Hansen orebody. Several potential source rocks for uranium are present and range in age from Proterozoic quartz monzonites of Silver Plume age to lower and upper Oligocene ash-flow and ash-fall tuffs. Uranium may have been contributed to the Hansen orebody several times from different sources. Uranium and thorium analyses of ash-flow tuffs indicate that ample uranium was released during cooling and ground-water leaching to form several Hansen orebodies. The host sandstones are conspicuously altered, and their initial high permeability has been greatly reduced by precipitation of intergranular cements, especially clays and opal C-T. The alteration and cementation mineral assemblages and the chemical composition of stagnant ground waters recovered from pump tests indicate that uranium deposition occurred under alkaline, reducing conditions preceded and/or accompanied by bacterial production of framboidal pyrite.

Jan 1, 2013

By Patrick Sullivan

Over the past few years, successful operations for processing phosphates employing the Grate-Kiln System have been achieved. Control and instrumentation philosophy followed in these installations are described and analyzed. Concepts utilizing digital techniques and computer systems appropriate for similar installations are also discussed.

Jan 1, 1967

By Nikhil Dhawan, Shrey Agrawal, SHAILA MIR

The current study investigates the effect of microwave processing on low-grade banded iron ore using charcoal, coking coal, and non-coking coal. Charcoal showed better microwave heating response at low temperatures, and the coals exhibit better heating response at higher temperatures. Low carbon dosage ~ 12% is sufficient to generate concentrate with 61.8% iron grade and ~6% for 94.8% iron recovery comprising of magnetite phase suitable for iron-making applications. The process separation efficiency of ~ 95% is achieved at 6% carbon dosage and decreases with an increase in carbon due to formation of the fayalite phase. The metallization degree showed a strong dependency on reductant dosage and achieved amaximumvalue of 22.7%at 18%charcoal. The comparison of ore with pure iron oxide and the synthetic mixture of iron oxide indicated that the underlying bonding due to banded structure enhances the Joule heating during microwave irradiation and thereby aids in attaining higher temperature and better separation.

Sep 21, 2020

By Thomas P. Meloy

Comminution is an old art. Unfortunately the analysis of the unit operations has been handicapped by the lack of both theoretical and experimental information. Two types of infor¬mation are needed, one an understanding of what happens when a particle breaks in a brittle manner; and two, an understanding of what happens when the daughter fragments pass through the mill. This paper is concerned with the former, the catastrophic fracture of a brittle solid. Recently, successful theoretical attacks on the frac¬ture of brittle solids have yielded significant-results. New experimental techniques are yielding insight into the physical phenomenon occurring during brittle fracture. Many of the re¬doubtable shiboliths of the last century are either being laid to rest or verified.

Jan 1, 1965

By J. D. Miller

The fossil resins of certain western coals are of significance and of sufficient value as a chemical commodity to justify a fossil resin industry. At the present time these valuable fossil resin resources, worth more than $0.50/lb as a chemical commodity, are being burned as fuel for electric power generation. This waste of our fossil resin resources corresponds to a loss in revenue of $200 million per year -equivalent to the value of the coal itself! Improved process technology for the recovery of fossil resin is under development and includes selective flotation of fossil resin from fine coal streams and solvent refining of the fossil resin flotation concentrate to produce a premium resin product. The most recent developments in process technologies are discussed with respect to separation efficiency and product quality. It is clear that the development of a fossil resin industry should not be limited by process technology.

Jan 1, 1994

By M. Ghiani

Biohydrometallurgy originated, some forty years ago, from an environmental problem, namely the serious pollution of the Ohio river by acid drainage water coming from neighboring subbituminous coal mines. Studies aimed at elucidating the cause of the intensive oxidation of the iron sulfide (pyrite) inclusions of those coals, led to the discovery of a bacterium, Thiobacillus ferrooxidans (Temple and Colmer, 1951), capable of acting as a catalyzer, accelerating the otherwise very slow chemical oxidation of iron sulfide to rates many orders of magnitude higher. However, it is now recognized that the biotechnology of microbial mining dates back to 1963, when the ability of this bacterium to solubilize copper from sulfide ores was ascertained (Razzell and Trussell, 1963). Much research has been carried out on biohydrometallurgy over these last 25 years and is still being actively conducted all over the world. The interdisciplinary nature of this young branch of science and technology is reflected by the variety of experts involved: microbiologists, mining engineers, hydrometallurgists, physico-chemists, mineralogists, solid-state physicists and biochemists. This intensive research effort has provided a solid background on the fundamentals of this technology, although many important issues have still to be solved, amongst which the enzymatic mechanisms controlling biocatalysis of mineral sulfides dissolution, the influence of bulk- and surface solid-state physics of metal sulfides on dissolution mechanisms, the interaction of the various strains composing natural microbial floras. Their elucidation should permit the rationalization of biohydrometallurgical techniques and the optimization of commercial processes. Biohydrometallurgy has already achieved satisfactory results: copper recovery from submarginal copper sulfide run-of-mine ores (i.e. assaying less than 0.3% Cu) by in-situ, dump and/or heap leaching is successfully practised in many countries and uranium recovery through bioleaching is competitive with other leaching processes.

Jan 1, 1987

By D. L. Ealy

At the Beckley Mine in southern West Virginia, forecasting unstable roof conditions in advance of mining is accomplished by using a rating system that combines historical information on mine roof failures with known mine geology. Failure frequency rates are derived for each category of roof rock composition, unit thickness, structure, and extraction ratio. In this manner, known geological environments are rated according to instability based on actual experience. Drill hole control and geological interpretation provide the basis for forecasting unstable conditions beyond working faces. The forecasting technique has assisted mine management in reducing fall frequencies by 80% over the past two years compared to the first five years of operation. This reduction in fall frequency was accomplished by modifying the plan of advancing sections to minimize mining exposure to unstable roof conditions.

Jan 1, 1980

By F. B. Brost

In 1976, a decision was made by Anamax Mining Company to install an unusual conveying system to transport ore 10.3 km (6.4 mi) from the new Eisenhower Mine to the Twin Buttes concentrator. The system, supplied by Cable Belt Limited of the United Kingdom, represents a radical departure from conventional belt conveyors. The driving tension is applied through two endless wire ropes driven by a single 2 240 kw (3 000 HP) drive while the belt acts only as the ore carrying medium. Full production was begun in January, 1979. Start-up problems hampered production for several months but were resolved by a joint Anamax-Cable Belt effort. The system has been operating at design capacity for 4-1/2 years, and has proven itself as a reliable, low cost ore transportation system.

Jan 1, 1984

By H. M. Garrett

Dr. Ft: L. Handy of Iowa State University's Engineering Experiment Station very handily reduced the relatively complex cement making process to ultimate simplicity: "Take two cups of crushed limestone; add one-half cup of clay or pulverized shale (plus perhaps some sandstone or iron ore; depending); mix thoroughly and grind up fine. Bake in white-hot oven at about 2,600 F. Cool. Add a tablespoon of gypsum: and, again, grind very fine. If you can do this for about a penny a pound, you can almost compete.' Before Dr. Handy's time, is the early days of the U. S. Cement Industry, from 1817 when the Erie Canal was started to 1895 when the first rotary kiln was built, this was the recipe, more or less. Dr. Handy's raw materials were deposited in a natural "cement rock" found in the Hudson, New York and Lehigh, Pennsylvania valleys. At first the natural rock was pulverized (not ground fine) and interlayed with wood for "baking" at about 1,800° F in a batch process vertical shaft kiln or beehive oven; then the calcined pozzalonic (lime and silica) product was cooled and ground fine for shipment in wooden barrels. Later, in 1871, true portland cement was made. The same natural rock was ground fine to make briquettes; interlaced with wood or coal in the "Beehives"; and baked at a clinkering temperature of about 2,6000 F to produce clinker (calcium silicates) which was ground fine for sale. In those days, the crude cements dropped in price from over 1 cent to 1/2 cent per pound. In 1895 the rotary kiln introduced-continuous instead of batch processing. The countercurrent process allowed the same raw materials (now finely ground to about 80% minus 200 mesh like face powder) to be fed at one end of the rotary kiln. Heat from a coal burner was introduced with combustion air at the other end to produce the requisite clinkering temperature. The clinker product was discharged for atmospheric cooling, mixed with gypsum, and again ground fine as face powder. The cement was sold primarily in barrels, later in jute or cloth bags, then paper bags, and now primarily in bulk truck and barge carriers. The price dropped to a 1/4 cent per pound by 1910, but with recent inflation it now sells for 2 cents per pound.

Jan 1, 1978

By Charles B. Dugger

Sacrificial linings for grinding mills have been a necessary state of the art of mineral dressing since the inception of comminution. Long recognized as the final link in energy transmission from power line to ore, mill liners as a scientific endeavor have not expanded as rapidly as other branches of mineral dressing engineering. Several reasons for this technological lag are apparent. Typically in the past, labor intensive foundries were freely located geographically, at a time when transportation charges made up a significant portion of the casting cost. Alloying agents had not gained their current level of sophistication and were relatively inexpensive in the quantities required. Precise foundry controls were not economically justified, or totally understood. Coincidental to these elements, liner consumption per unit processed did not categorically contribute as a major cost item to the mill operator. Grinding equipment was small, and many times lining life exceeded that of the promoter. These unique conditions no longer exist. Ore dressing equipment has grown to meet modern mining demands. Larger processing facilities, utilizing fewer pieces of equipment, have replaced operations of the past. Emphasis today and tomorrow is on larger and larger equipment, with an eye on lower and lower unit processing costs.

Jan 1, 1979

By John J. Dwyer

As one begins to contemplate the organization of a talk with the title "Iron Ore - The Permanent State of Evolution," the main divisions appear to be the past, the present, and the future. But distaste for repetition of the present production achievements, which scarcely need additional description on this occasion, soon leads one to the conclusion that a more appropriate division of the subject is simply the past and the future . . . with emphasis on the future. We are working in the present, but it can only be understood by what has taken place in the years and decades gone by, and/or under what terms we will have to face the future. Evolution is more often thought of as a steady change - but steady change is really the product of revolutions, sometimes making headlines but often unnoticed at the time. With hindsight, we recognize the great importance of the emergence of the Bessemer converter and the open hearth and the vast influence that both have had on steel making and the changing ore demand. In this country we also see schooners opening the era for lake transportation of iron ore from Michigan to Take Erie. Later, steamships haul the ore from the Mesabi Range to the steel centers of the country. In order to take full advantage of the inland seaway, there had to be revolutions in ship design, loading and unloading facilities and channel and lock development. Full scale utilization of the resources of the Mesabi Range, itself, required parallel upheavals such as the development of new production equipment, and substitution of modern forms of energy for horsepower, and, yes, manpower, as well.

Jan 1, 1968

By K. W. Morris

Of the fossil fuels used for power generation coal is by far the most variable and complex in its properties. A thorough review of the characteristics of the coal to be fired is essential before boiler design can begin. Major parameters such as heating value, moisture content and ash properties will determine not only the boiler size and configuration, but also the performance of the unit with respect to the thermal efficiency, particulate and gaseous emissions, and unit availability and reliability. An example of a review completed on a large low-rank coal deposit for a power plant will be described.

Jan 1, 1983

By E. Wm. Heinrich

Glass sands fall into that extremely select category of mineral deposits that requires a fantastic degree of natural concentration (95% +) of a single component before they can even be considered as ores suitable for further refinement. The combination of geological factors that has produced such an environment of "mineralogical single-mindedness" has appeared only rarely. Factors that require consideration in the economic evaluation of a potential glass-sand deposit can be grouped into three categories: 1) geological (e.g., size, shape, structure); 2) petrographic (e.g., grain size, accessory minerals, nature of iron contaminants); 3) geographic - political (e.g., proximity to consumer, size of market, zoning restrictions). Of particular con ern is the nature of the iron contamination. Iron-bearing species appear as 1) accessory mineral grains, either detrital or authigenic, 2) cements, 3) grain coatings, and 4) quartz-grain inclusions. Selection of the cheapest form of beneficiation requires precise information on the mineralogy of the iron species and their detailed petrography. Because of the antipathetic relationships, in many parts of the United States and Canada between the geographical locations of glass plants and the geological distribution of glass sands, the selection of ac suitable source for a particular glass plant may be dichotomous. One may seek either an exceedingly pure "classic" type glass sand that is relatively distant and whose cost includes a major transportation charge or a relatively proximate and somewhat "impure" source whose cost includes a substantial fee for beneficiation.

Jan 1, 1974