Search Documents

By L. Yuan

In the U.S. coal mining industry, most spontaneous combustion fires occur in longwall or worked-out gob areas. In order to reduce the fire hazard caused by spontaneous combustion, it is important to understand how ventilation and gob characteristics affect the spontaneous heating process. Given the difficulty to conduct field tests in such an environment, a computational fluid dynamics (CFD) study was conducted to investigate the effects of ventilation and gob characteristics on the spontaneous heating process in longwall gob areas. Two longwall panels with a bleeder ventilation system were simulated. The spontaneous heating is modeled as the low-temperature oxidation of coal in the gob using the Arrhenius rate law and kinetic data obtained from previous laboratory-scale studies. The heat generated from the spontaneous heating is transported by convection and conduction, and oxygen and the oxidation products are transported by convection and diffusion. Unsteady state simulations were conducted with different ventilation conditions and gob permeability distributions. The ventilation parameters varied in the simulations are the pressure at the bottom of the bleeder shaft and regulator resistance in the second entry inby the longwall face.

Jan 1, 2009

By Alan Weakly

The Powder River Basin (PRB) of northeastern Wyoming and south-central Montana is the largest strippable reserve of compliant coal (0.6 or less lb of sulfur per million Btu) in the United States. In mining parlance, it is the Mother Lode! Wyoming’s portion of the Basin provides one fifth of the coal produced in the United States annually, and the state has been the nation’s top coal producer for the past six years. Based on 1993 production statistics and estimated strippable compliance coal reserves, Wyoming may remain the nation’s top producer for the next 76 plus years. Past articles on the PRB have focused mainly on production. After living and working in the Basin for the past five years, I have developed an appreciation for the area and its major industry that transcends size and production data. In the fall of 1993, MINING ENGINEERING’s publisher and I decided to present a series of articles that would cover many other aspects of the Basin. Ten topics were outlined, and specific individuals, selected for their knowledge and experience, were asked to contribute articles about their specialties. Although Montana has four large mines producing coal from the PRB, this series of articles will concentrate on the Wyoming portion of the Basin.

Jan 1, 1994

By F. Freme

Coal production in the United States reached a record level in 2005, ending the year at 1.03 Gt (1,133.3 million st) according to preliminary data from the U.S. Energy Information Administration (Table 1). Production in 2005 was 19.2 Mt (21.2 million st) higher than the 2004 level of 1 Gt (1,112.1 million st) and surpassed the prior record set in 2001 by 5.1 Mt (5.6 million st). Although total U.S. coal consumption rose in 2005, not all coal-consuming sectors had increased consumption for the year. Coal consumption increased in the electric power sector by 2.2 percent and declined in the other industrial sector, while coking coal consumption decreased slightly.

Jan 1, 2006

By J. F. Lupo

Heap and valley leach operations rely on solution collection piping placed within the heap to enhance both solution recovery and to assist overall solution management. The most common piping used in leaching operations is solid or perforated High Density Polyethylene (HDPE) pipe and Corrugated Polyethylene pipe (CPE). These pipes are widely used because of their low cost, ease of installation, durability, and flexibility. The typical recommended maximum design depth of burial for HDPE and CPE pipes is on the order of 30 meters (100 feet). However, ore heap heights at many facilities exceed 30 meters and some are now approaching 180 meters (600 feet) in height. At very high ore heap heights, the stability and performance of HDPE and CPE pipes becomes a critical issue for leaching facility design and operation. Failure of solution collection piping can lead to poor solution recovery, high hydraulic heads on the liner system, and in some cases, unstable ore slopes due to high solution pressures near slopes. This paper presents a review of methods that have traditionally been used to evaluate pipe stability under high normal loads. A common shortcoming of these methods is the inability to account for beneficial effects of ore arching around pipes and the time-dependent creep (stress relief) behavior of polyethylene (PE) materials. A new analytical approach is developed and presented which includes the effects of ore arching around pipes and creep of PE materials. The results of the new approach show that PE pipes will deform under high heap loads, but can remain stable and functional. Pipe stability is shown to be dependent on the type of pipe backfill and initial backfill compaction. The new approach represents a useful tool for designing applications for PE pipe under high normal loads.

Jan 1, 2001

By J. T. Bartlett

Life-of-mine process simulation is an interdisciplinary effort and a useful means of thoroughly evaluating mining and minerals projects. Communication between geologists, mine planners, miners, metallurgists, and managers not only benefits each discipline but facilitates design of an efficient operation and allows for accurate forecasting of productions and cash flow. By focusing on the key areas: geology; mine design; waste dumps; stockpiles; metallurgy; weather data; tailings disposal; using contours, block models, mine plans, process flowsheets, design criteria, operating and control strategies, maintenance schedules, and operating costs to perform detailed daily simulation from start-up to shut-down; a comprehensive understanding for all disciplines is achieved. Construction of a METSIM model that includes all test work and project data from drill holes through net present value calculations brings the pieces together to achieve optimum process design, minimize operating problems and eliminate the term ?black box? from project meetings and discussions.

Feb 27, 2013

By N. P. Widodo

The ventilation measurements by tracer gas method at Pongkor gold mine show that effective diffusion coefficient, E, at straight airways indicated a similar range of measured one by the laboratory experiments which can be estimated by Taylor equation. On the other hand, E of the curved airways in the mine was estimated as larger than that of the straight ones (1.5 to 32 times than that obtained by the Taylor equation and these have been compared with the data measured in Kushiro coal mine, Japan). The curved mine airways, with small curvature against airway radius and complex velocity profile, possibly give concentration ? time curves with long tailings, thus those airway conditions could make larger E. Laboratory experiments of gas diffusion by a pulsed injection of small amount gas, into straight and curved airways, have been conducted in order to investigate a range of E in mine airways. The plots of E against Reynolds number show that the present laboratory results of straight-long airways are almost close to one calculated by Taylor equation. On the other hand, the values of E measured at curved single-direction airways were smaller than that of the straight airways, which may be due to effects by secondary vortexes flow in the curved airways.

Jan 1, 2009

This paper evaluates the effect of longwall mining on a cluster of unconventional shale gas wells located in a district barrier pillar between a current longwall panel and the future panel north of the barrier pillar. A cluster of 19 unconventional shale gas wells have been drilled and 5 additional gas wells have been proposed in the barrier pillar. The closest gas well is 25.6 m (84 ft) to the current panel tailgate and 26.2 m (86 ft) to the tailgate of the future panel north of the barrier pillar. The rib-to-rib width of the barrier pillar is 57.9 m (190 ft). The distance between the two gas wells across the barrier pillar is 6.1 m (20 ft). The pillars in the current tailgate are on 22.9-m (75-ft) and 32.0-m (105-ft) centers, and the pillars in the tailgate of the panel north of the barrier will be on 22.9-m (75- ft) and 36.6-m (120-ft) centers. The two longwall panels adjacent to the barrier pillar are 475.5-m (1,560-ft) wide. The overburden depth at the shale gas well site is 321.6 m (1,055 ft). The wells have been installed in the barrier pillar, and the current district panel and subsequently the panel north of the barrier will be developed and retreated in the near future. The average min

Jan 7, 2020

By V. Kecojevic

Environmental and economic costs related to equipment fuel consumption and carbon dioxide (CO2) emission present a substantial challenge to the mining industry. Haul trucks are an integral part of the overall surface mining system and they consume a substantial quantity of fuel. Consequently, they produce a significant amount of CO2. The objective of this research is to (i) establish a mathematical relationship among a truck?s fuel consumption, power and engine load factors and (ii) determine the amount of a truck?s CO2 emission and the associated cost that may arise from potential CO2 legislation. In order to achieve these objectives we have considered original equipment manufacturer (OEM) haul trucks, commonly used in surface mining operations. The research presented here may be used by mining professionals to help determine the cost and environmental burden of the trucks? application, and efficiently manage energy consumption.

Jan 1, 2011

By S. Jayson Ripke, Shane Hoff

Cleveland-Cliffs’ Northshore Mining Company operates a magnetic iron ore (taconite) concentrator and pelletizer in Silver Bay, MN. These are two recent cost reduction projects: 1. Rougher Magnetic Separators were upgraded throughout the concentrator; throughput and recovery were simultaneously improved. 2. Green Ball Roll Screens on one agglomeration circuit were upgraded from 3.5-inch to 2.5-inch rolls. Throughput improved by 24% from 62 to 77 LTPH. Green ball size distribution improved as an added benefit.

Jan 1, 2005

By Kimberley MacHardy, Ann Maest, Greg Lawson, James Kuipers

Although water quality predictions are often made in Environmental Impact Statements (EIS's) as part of the National Environmental Policy Act (NEPA), comparisons between predicted and actual water quality conditions are rarely reviewed. A comprehensive review of predicted and actual water quality conditions was conducted for a number of large U.S. hardrock mines with EIS’s. For mines with large differences between predicted and actual conditions, factors responsible for the deviations, such as characterization and modeling errors or engineering failures, were identified. Recommendations are made for how the NEPA process could be modified to better predict water quality at hardrock mine sites.

Jan 1, 2005

By M. K. Mohanty

One of the main objectives of this study was to evaluate a fine-coal cleaning circuit using an enhanced gravity separator specifically for a high sulfur coal application. The evaluation not only included testing of individual unit operations used for fine-coal classification, cleaning and dewatering, but also included testing of the complete circuit simultaneously. At a scale of nearly 2 t/h, two alternative circuits were evaluated to clean a minus 0.6-mm coal stream utilizing a 150-mm-diameter classifying cyclone, a linear screen having a projected surface area of 0.5 m2, an enhanced gravity separator having a bowl diameter of 250 mm and a screen-bowl centrifuge having a bowl diameter of 500 mm. The cleaning and dewatering components of both circuits were the same; however, one circuit used a classifying cyclone whereas the other used a linear screen as the classification device. An industrial size coal spiral was used to clean the 2- x 0.6-mm coal size fraction for each circuit to estimate the performance of a complete fine-coal circuit cleaning a minus 2-mm particle size coal stream. The ?linear screen + enhanced gravity separator + screen-bowl circuit? provided superior sulfur and ash-cleaning performance to the alternative circuit that used a classifying cyclone in place of the linear screen. Based on these test data, it was estimated that the use of the recommended circuit to treat 50 t/h of minus 2-mm size coal having feed ash and sulfur contents of 33.9% and 3.28%, respectively, may produce nearly 28.3 t/h of clean coal with product ash and sulfur contents of 9.15% and 1.61%, respectively.

Jan 1, 2008

Microorganisms are finding more use in the mineral industry, with extensive research efforts being reported in 1991. Most of these research efforts were presented in two major meetings, the SME Annual Meeting in Denver (February, 1991) and the Engineering Foundation Conference about Mineral Bioprocessing in Santa Barbara (June 1991). In addition, several articles were published in the IMM Transactions, Minerals and Metallurgical Processing and Water, Air. and Solid Pollution Journal. The literature can be categorized as: • Review articles presenting an overview of the activities in the use of biotechnology in mineral processing. • Research efforts into genetic manipulation of microorganisms to perform a specified job. • Studies in bioleaching of metals from different types of ores. • Biotreatment of wastes from the mineral industry including acidic mine waters, uranium tailings, cyanide destruction, etc. • Investigations into the role of microorganisms in the energy materials, such as oil, coal, tar sands, oil shales, etc. Smith (Mineral Bioprocessing Conference) presented a review of research efforts as well as practical applications of biotechnology in the mineral industry. In another article, Smith et al. (Minerals Engineering) emphasized that extensive fundamentals and applied research work should be pursued to explore the fundamentals, potential and practicality of the various possible uses of microorganisms in mineral engineering.

Jan 1, 1992

By Farrukh M. Mazhar, Philippe P. Martin

Electrical Vertical Sounding (EVS) profiling has proven to be a valuable tool to set the alignment and guide the design of a 17 km-long, 4.7m diameter water-conveyance tunnel in the Peruvian Andes at an altitude of 4,260 m. EVS profiling helped determine where to locate boreholes, and reduce the amount of drilling to 1,200 m of vertical and inclined boreholes. EVS profiling allowed the designer to identify and verify by drilling the existence of zones with difficult tunneling conditions that were avoided by realigning the tunnel. The rock quality was checked by drilling and a combined scheme of excavation by TBM and conventional drill and blast technique was developed for the final design.

Jan 1, 2003

By Rolland R. Mates

This paper describes the use of post- tensioned rock anchors to reduce the risk of future damage to a residential structure as a result of coal mine subsidence. The project described in this paper was performed by the Office of Surface Mining Reclamation and Enforcement (OSMRE) of the U. S. Department of the Interior. The OSMRE was created to administer Public Law 95-87, the Surface Mining Control and Reclamation Act of 1977. The responsibilities of OSMRE include "reclamation and restoration of land and water resources, adversely affected by past coal mining including prevention, abatement, control of coal mine subsidence. ?('l) Consequently, OSMRE has been addressing mine subsidence problems since its initial subsidence stabilization project in 1979. Stabilization activities have primarily consisted of supporting the overburden material by injecting materials through drilled bore holes into the underground mine voids. Injection of various materials into mine voids, including fly ash mixtures, coal refuse, cement grout, and gravel has proven to be a successful method of reducing mine subsidence-related surface movements, and has been extensively utilized in mitigating mine subsidence problems. However, the cost of drilling for injection can be extremely high in areas where the depth to the coal seam is great.

Jan 1, 1986

By J. P. H. Steele, M. U. Ozbay

As mining operations progress toward tele-mining and autonomous procedures, the need for machine performance monitoring increases. Presently, through a combination of vision, sound, and other subjective observations, an operator attempts to optimize the mechanical excavator’s operation. As the operator is moved away from the face in the case of tele-mining or completely removed for autonomous operation, the qualitative sensory input is lost. This lost information must be replaced with quantifiable sensory input. Chip formation detection may be a suitable replacement sensory input. Chip formation can be predicted with high confidence (>80%) through the analysis of the load waveform associated with the bit/rock interface.

Jan 1, 2002

By B. Gigas, M. Preston, M. Giralico

Optimized mixer settler designs will now handle total flows of over 6,000 m3/hr.Computational Fluid Dynamics (CFD) is a timely and predictable tool for design development. Lightnin has the capability of using numerical analysis methodology to evaluate flow patterns and phase separation. CFD can show performance differences between changes, in mix tanks, in settler geometry, and in liquid depth, against variable flow rates. Understanding the differences allows the development of optimized designs. This paper focuses on the major design components of the mixer settler and how technological advances will lead to further improvements, when designing for today’s largest flow plants.

Jan 1, 2004

By J. M. Wempen

As development in underground coal mines progresses away from the critical components of the ventilation system, including the main fans and ventilation shafts, resistance is markedly increased. This results in higher pressure and flow requirements from the main fan(s) to maintain adequate face ventilation, which often requires that the primary ventilation system is upgraded with additional shafts and surface fans. The use of booster fans underground is a potentially practical alternative. This study presents simulations of the use of booster fans in two underground ventilation scenarios, one longwall and one room and pillar. The booster fan effects on the power requirements of the ventilation systems are evaluated.

Jan 1, 2011

By J. B. Seymour

This paper provides an overview of the current use of backfill for ground support in underground metal mines in the United States and a summary of recent accident data reported for these mines by the Mine Safety and Health Administration (MSHA). Backfill mines comprise a major part of the underground metal mining industry and are particularly important in terms of the fatalities and injuries impacting this workforce. Ground falls are the leading cause of fatal accidents at these mines accounting for 50 percent of the total fatalities (4 out of the 8 fatalities that occurred from 2006 through second quarter of 2011). MSHA reported several different types of accidents involving backfill at these mines. While backfill ground falls do not occur frequently, these accidents result in a much higher proportion of fatalities than host rock ground falls. Backfill ground fall accidents are especially hazardous in underhand cut-and-fill mining operations where employees work directly beneath the backfill. An analysis of recent MSHA accident data supports the need for further cooperative research with the mining industry to identify and address ground control problems in underground metal mines using backfill.

Feb 27, 2013

By R. C. Freas

Composite materials are finding new applications daily, ranging from automotive parts to synthetic lumber. The variety of applications seems almost limitless. However, these emerging products bring both new opportunities and new challenges to the field of industrial minerals. One of the primary challenges is from alternative materials other than industrial minerals. Thus the question is asked whether industrial minerals will truly benefit from the growth in market applications for composite plastics. This article highlights some of the opportunities for industrial minerals while focusing on performance and competitive demands on mineral products intended for use in this developing market.

Jan 1, 2000

By John E. Newby

The Brightwater Conveyance System consists of four tunnel segments in three tunnel con-tracts, comprising over 21,760 m (71,400 ft) of pressurized face tunneling in complex glacial and non-glacial soft ground conditions with a large proportion 60 m (197 ft) or more below the ground surface with up to 7 bars groundwater head. This resulted in unique technical challenges for establishing geotechnical baseline values. The process used to develop these baseline values and specifications with regard to the level of risk that the owner, King County, was willing to accept is described in this paper.

Jan 1, 2008