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By Jie Li, Longxiang Li, Wenbing Guo, Gaobo Zhao, Yuhang Hu

Surface subsidence caused by underground longwall mining is a very complicated process in time and space, influencing building and structures on the surface of the mining area, including houses, pipelines, and highway. The field monitoring data of surface subsidence are essential for protecting them. This study investigated the dynamic and residual subsidence characteristics of both the surface and the highway over a 730-day monitoring period on a longwall panel. Three monitoring lines (Lines 1–3) were established to monitor the subsidence process, and three stages were identified: initial stage of surface subsidence, active period of surface subsidence, and residual subsidence deformation stage. The maximum subsidence value on the highway (1,786 mm) was smaller than that on the surface (2,094 mm), and the maximum subsidence velocity on the highway (41.7–50.8 mm/day) was also lower than that on the surface (66.7 mm/day). During the residual subsidence deformation stage, both the surface and highway subsidence velocities decreased to below 0.6 mm/day. Furthermore, differences in subsidence characteristics between the surface and the highway were analyzed, with the subsidence value on the highway always being less than that on the surface, while the subsidence velocity during the residual deformation stage was not always lower. This could be attributed to the influence of dynamic loads from vehicles, which could induce additional residual subsidence on the highway. Further investigation into this phenomenon will be conducted in future research.

Jul 1, 2023

By J. Snowberger III

Rhenium is a valuable and extremely rare chemical element with unique chemical properties. It is extracted commercially as a byproduct from the processing of molybdenite associated with porphyry copper ores. There is a present interest in recovering rhenium from copper pregnant leach solutions (PLS) produced by copper heap and stockpile leaching. These solutions contain rhenium at very dilute concentrations, typically in the 1 mg/L concentration range. This paper describes laboratory column ion exchange experiments to extract rhenium from these solutions using weakly basic anion exchange resins and actual plant PLS from two operating mines. The dynamic loading and elution behavior of Re on Purolite® A170 and A172 is discussed.

Feb 23, 2014

By Michael Murphy, Mark Van Dyke, VASU GANGRADE, Brent Slaker

Room-and-pillar mining in multi-level underground stone mines come with unique pillar stability issues. The pillar stability in these mines primarily depends on the thickness of interburden between mining levels and the staggering of pillars. NIOSH has previously established pillar design guidelines for shallow, flat-lying mines and single-level operations, but there is little guidance for ground control design in multiple-level stone mines. Therefore, to improve the overall understanding of ground control in these mines, a microseismic monitoring system has been installed at a multi-level underground stone mine in Tennessee with up to a 243-m overburden and a 7-m interburden thickness between levels. The microseismic system is comprised of nine uniaxial accelerometers and one triaxial accelerometer installed in the interburden. The seismic array is locally focused with all sensors installed within a 625 m2 area and is setup to monitor the seismicity around the formation of the pillar in the lower mining level. Data is collected over 11 months and comprises of over 1,000 high-confidence events that have been located in the study area comprised of post-blast activity. The event locations were identified using a 3D-velocity model, with an average 4-m location accuracy for this array calculated using the system data. Most observed seismicity was on the excavation boundary, both in the interburden and in the roof of the top level. At this stage of analysis, there are no significant rock failures with which to correlate seismicity, but event locations correlate well with presumed damage in the vicinity of blasts.

Apr 26, 2022

By D. S. Bird

The Kennecott Utah Copper Modernization Project, initiated in 1986, was directed to provide an expansion and modernization of mining and process facilities at the property's Bingham Canyon Mine and ore concentrators. Major components in the project included installation of an in-pit ore crusher, transfer conveying system, and construction of a new copper ore concentrator with a design capacity basis of 70,000 tonnes/day. The Copperton Concentrator was commissioned in February 1988. A principal feature of the plant is the grinding circuit, comprised of three identical lines, each consisting of a 10.37 m (diameter) by 4.57 m (length) Semi-Autogenous Grinding (SAG) mill and two 5.54 m (diameter) by 8.62 m (length) ball mills. The SAG mills are driven by two variable-speed 9,000 kW DC motors coupled through a clutch-pinion gear-ring gear assembly. The ball mills are driven by 4,125 kW synchronous motors coupled through a typical clutch-pinion gear-ring gear system. The expansion and particularly the Copperton Concentrator performance was so successful that by early 1989, management began examining options to further expand production capacity. With regards to the concentrator, numerous alternatives were considered, ranging from installation of a grinding line similar to one of the existing lines, to a "super" line consisting of a 12.8 meter (diameter) SAG mill and a 20,000 kW motor with a capacity of 50,000 tonnes per day. The technical and economic analysis of the various scenarios indicated that one "large" 11.0 meter (diameter) by 4.88 meter (length) SAG mill with a production capacity of 32,000 tonnes per day and a 12,000 kW drive would be optimum. The key question to be answered in the project was whether to continue with the pinion-ring gear combination, or install a gearless drive. The following paper outlines many of the items that were evaluated in the mill selection process followed by actual plant performance, and a discussion of ongoing plant continuous improvement projects.

Jan 1, 1995

A case study of a systematic approach to grinding circuit steady-state optimization is presented. After overall review of the flowsheet, two circuits were prepared for detailed testing. Functional performance analysis was chosen as the primary modelling system, and on this basis a quality assurance program for data gathering was implemented. A number of circuit design and operating variables were experimented with statistical analysis of plant test results revealed relationships previously unquantifiable by any other modelling technique. Improvements in classification system and mill grinding efficiencies were demonstrated and significant energy cost savings thus realized.

Jan 1, 1998

By O. P. Sinha, Biswajit Mishra, A. K. Mandal, Raj Kumar Dishwar, G. S. Mahobia, Ram ji Omar

Most of the mineral deposits found in North-East India remain unexploited due to inadequate knowledge on their status, economic viability, and requisite mining technologies. The aimof this study is to characterize the multimetallic magnetite mineral deposit from the Nagaland area in India. The quality of iron ore was evaluated to establish its suitability as a raw material for iron production. Detailed studies were conducted to establish the composition and properties of the samples. X-ray diffraction (XRD), X-ray fluorescence (XRF), electron probe micro-analyzer (EPMA), and petrographic microscopy techniques were employed in the investigation. Shatter and tumbler test was performed for analyzing the mechanical properties of the ore. XRD studies indicated that magnetite is the major mineral with low amounts of martite, maghemite, and quartz. XRF/EPMA results indicated that magnetite contains 35–65 wt.% of iron and 1–5 wt.% of chromium. It also confirms the presence of Ni and Al up to 1 wt.% and Si up to 6 wt.%. Chromite-rich ore contains up to 30 wt.% Cr and 15–20 wt.% of Fe.

May 10, 2021

By E. Bloomstein

The Lone Tree gold mine is located about 4S kilometers east from Winnemucca on the west flank of Lone Tree Hill in Humboldt County, Nevada. The deposit occurs at the north end of the low, rolling Havallah Hills and is about 1 kilometer south of Interstate Highway 80, in sections 11 and 14, Township 34 North, Range 42 East, Mount Diablo Base and Meridian (Fig. 1). The Lone Tree deposit is outside of any previously established mining district and all lands are owned or controlled by Santa Fe Pacific Gold or affiliated companies.

Jan 1, 1993

By R. R. Hall

Tests were conducted to assess the potential of column flotation for beneficiation of a talc ore from Montana. This ere contained approximately 80% talc, with the gangue comprised mainly of chlorite, silica, and dolomite. A tributylamine, MIBC, and sodium silicate reagent suite proved effective for talc flotation. Rougher-cleaner column flotation in a continuous open-circuit produced a final talc concentrate which contained 0.90% Al2O3. 0.17% CaO, and 1.28% Fe2O3. These analyses represented impurity rejections of 77, 85, and 65%, respectively. Weight recovery for this open-circuit was 52%; however, weight recovery was estimated to be 75% with cleaner tailings recycle. Results from this investigation show that column flotation is a viable means for beneficiating talc.

Jan 1, 1990

By A. Haghighat

The Missouri University of Science and Technology?s (Missouri S&T) Experimental Mine is a teaching and research facility which has been excavated in limestone by mining engineering students over almost 100 years. The mine is currently being extended to a second level. Available fans for ventilation are two surface fans of 24 kW and two underground booster fans of 12 kW. The design of a ventilation network in conjunction with multi surface fans and booster fans entails a complex procedure. Ventsim Visual software modeling has been used for network analysis to determine the optimum surface and booster fans locations, blade settings, and speeds. Both natural and mechanical induced ventilation pressures have been taken into account. Three working faces on each level have been designated as target points that minimum air quantities are required. The model has been calibrated against a pressure and quantity survey. Design of ductwork, door/stopping positions and different fans characteristics have been examined. The optimum flow rate at identified working faces, efficiency and minimum energy losses and annual network power cost determine the best scenario. The optimum design has been determined for the ventilation network for the next 100 years. The optimum flow rate across working faces is the key criterion selected.

Feb 23, 2014

By Andrew Trusiak

Brunswick Mining, employing approximately 1600 employees, is located 40 km south of the city of Bathurst in north eastern New Brunswick. The mine has operated as two lead-zinc operations - the underground mine(No.12) and the open pit mine (No.6). The open pit orebody is presently being' mined by underground methods. It is expected that the No.12 mine will furnish the entire ore supply by the end of 1981. The flotation practice prior to 1971 has been described by Neumann and Schnarr(1) and by Erskine (2). More recently, the current flotation practice has been described by McTavish(3) and deals with some major circuit modifications between 1972 and 1978. The period 1978 to 1980 has seen the completion of. a major flotation cell replacement and expansion program for the No.6 concentrator, and the implementation of computer control in the No. 12 CuPb and Zn flotation circuits.

Jan 1, 1981

By Fitzhugh T. Lee

Results from the first part of a two-part investigation of the stability of highwalls in open-pit coal mines in the Paleocene Fort Union Formation of the western Powder River Basin of Wyoming and Montana indicate that these highwalls are subject to time-dependent deformation. Field investigations and laboratory physical properties tests of coal and overburden rocks suggest that several factors influence highwall stability. Some of these factors are rebound of overconsolidated rocks, desiccation, water, orientation and spacing of fractures, and strength and deformation properties. Factors of safety for a typical highwall in the study area (calculated by the finite element method) may be less than 1.0 when open fractures are present and the highwall has degraded. Although it is concluded that most open-pit highwalls in the Fort Union Formation within the study area have adequate short-term stability, these highwalls do deteriorate and become progressively less stable. Because of this, postmining failures are common and stability conditions could become critical if mining were delayed and then resumed after a period of several months. The second part of the investigation will utilize field measurements of rock-mass properties and instrumentation of actively mined highwalls to obtain data for comparison with the results of the initial investigation. Because the height of highwalls will increase as the more shallow coal is exhausted, these data will also be used to predict the behavior of slopes higher than those presently found in the western Powder River Basin.

Jan 1, 1977

By R. C. Bunge

A magnetogravimetric separation is the consequence of two competing forces with opposing directions, i.e., magnetic buoyancy and gravitation (or centrifugal force). While magnetic buoyancy is a function of particle volume, gravitational force depends on particle mass, thus permitting a separation according to specific gravity. Since magnetic buoyancy is not a phenomenon of common knowledge, this chapter is meant to briefly introduce the theory of magnetogravimetric separations. A particle that is suspended in a magnetic fluid which is exposed to an inhomogeneous magnetic field experiences a repulsive force -the so called magnetic buoyancy. In order to illustrate this effect, an analogy with the more familiar hydrostatic buoyancy is drawn. Hydrostatic buoyancy occurs due to unsymmetrical pressure distribution 'above' and 'below' a suspended particle (fig. 1).

Jan 1, 1990

By A. Noble

For the past 30 years, process flowsheet design has been accomplished largely through modeling and simulation. This approach provides circuit designers the freedom to test various separation approaches while minimizing physical and human resource requirements. The Limn® software provides a unique approach to process simulation, through a Microsoft Excel interface. While the software comes with standard process models for numerous unit operations, the Excel calculation environment and the accompanying VBA platform provide a convenient interface for custom model integration, even for non-experienced programmers. This feature is especially useful for university students in introductory process modeling and simulation-assisted flowsheet design courses as well as experienced practitioners with proprietary process models. This paper shows how the Limn® software may be used to solve basic process engineering problems as well as more comprehensive circuit design challenges. Industrial examples as well as opportunities for training and education are presented.

Feb 23, 2014

By C. J. Lewis

Considerable amounts of the world's known reserves of elemental sulfur are found near the surface in areas of volcanic activity both active and inactive. Because such deposits cannot in general-be mined by the well-known Frasch process, and because other methods of recovery have not proven to be economically competitive except in isolated instances, at present these reserves remain relatively undeveloped. However, projections of world sulfur demand indicate that new sources of marketable sulfur will be needed in future years 2/, 19/. For this reason, recovery of elemental sulfur from these near-surface deposits is of continuing interest. Solvent extraction as an approach to recovery of elemental sulfur from open pit-mined ores of these non-Frasch deposits has received considerable attention particularly at the research and development level 3 /, 7/, l l /, 16/, 21/,23/, 29/ This method has been and continues to be attractive because it presents the potential of high sulfur recovery and purity of product coupled with a relatively simple process flowsheet in which low energy requirements and reasonable operating costs are thought to be possible. However, the physical and chemical characteristics of the native-sulfur ores, of elemental sulfur, and of the known solvents, have presented difficulties in the development of solvent extraction processes. Up to the present time, viable processes have not been realized within the framework of sulfur marketing conditions.

Jan 1, 1970

By D. Akers

Many of the trace elements found in coal are associated with mineral matter, making it possible to remove them by physical coal cleaning. As part of work funded by the Electric Power Research Institute, both conventional and advanced coal cleaning processes were found to provide large reductions in the concentration of many trace elements that, if released into the atmosphere, are considered to be potentially toxic or environmentally harmful. Advanced physical cleaning technologies appear to provide greater reductions than conventional technologies. Chemical cleaning processes may also remove many trace elements, possibly including organically-bound elements such as beryllium. Care must be taken in the disposal of coal cleaning plant refuse because oxidation and leaching of this material can create highly acidic leachate and many trace elements are mobile in an acid environment. Laboratory leaching procedures are potentially useful in determining the degree of risk of water contamination by trace elements should an acid environment form.

Jan 1, 1992

By H. EI-shall

Bench top centrifuge is used to study the consolidation behavior of phosphatic clays. A mathematical model (based on first order kinetics) is developed to describe the relationship between the void ratio (at any time) and the effective stress. Permeability of the sediment as a function of the void ratio is also described. The obtained data are compared with that obtained by other consolidation testing methods. Centrifuge results indicate that consolidation data may be developed in a short period of time (hours) as compared to days or weeks when other techniques are used.

Jan 1, 1995

By R. Q. Honaker

Recent research has shown that enhanced gravity separators provide the opportunity to effectively clean I mm x 37 micron coal. At Southern Illinois University, a detailed experimental program was performed on a continuous Falcon Concentrator, which was found to achieve separations at mass throughput capacity values in excess of 100 tonnes/hour. The apparent particle separation density for I mm x 73 micron coal was about 1.60 with relatively high efficiency (Ep = 0.12). Typical ash and sulfur rejection values of 85% and 70%, respectively, were achieved while recovering 85% of the combustible material. Metallurgical and efficiency data from the evaluation are presented in this publication.

Jan 1, 1998

By Jon C. Yingling

Lean manufacturing, pioneered by Toyota, has been credited with the most significant improvements in production efficiency and product quality since the transformation from craft manufacturing to mass production in the early 20th century. It represents a comprehensive philosophy for structuring, operation, control, and management of production systems that is believed to have wide applicability. This paper outlines major lean manufacturing principles and discusses their potential for application in the mining industry.

Jan 1, 1999

By A. Noble

"In coal and mineral processing, several numeric parameters are used to quantify the separation performance of unit operations. For density-based separations, the partition curve is used as the starting point for many stages of diagnostic analyses. The curve is often quantified by its midpoint slope sharpness, and this single value is subsequently used for technical evaluation, benchmarking, and comparison. While this analytical approach does depict misplacement by relative density class, it inherently prioritizes middling separation and does not consider process economics or the micro-price value of individual classes. An alternative parameter, the organic efficiency, does indirectly consider process economics, but it does not reveal information on the root cause of lost revenue or misplacement. In this paper, a new analytical approach, the partition moment of inertia, is introduced. This parameter reconciles the technical misplacement data derived from the partition curve with the economic data derived from micro-pricing. The result is a new analytical procedure that promises better use of performance data. IntroductionPartition curves are commonly used in the characterization, evaluation and simulation of various physical separators. In mineral processing, partition curve analysis is routinely applied to hydrocyclones, screens, density separators and other beneficiation technologies that are based on intensive physical properties. Graphically, the partition curve depicts the recovery of particles as a function of the physical property on which the separation is based, such as particle density, size or magnetic susceptibility. Given the probabilistic nature of many real separators, the partition curve often exhibits a characteristic S shape (Fig. 1), similar to a cumulative normal distribution. Other geometric features of the curve are also depicted in Fig. 1, including the high and low closeout, or bypass, values; the midpoint slope; and the separation cut point, defined as the property value with 50 percent recovery.Partition curve analysis was originally proposed to evaluate coal washability (Tromp, 1937). Given the limited computational resources at the time, the analytical methods relied heavily on graphical construction and interpretation of the curve. Owing to the simplicity of calculation and interpretation, many of these graphical approaches are still widely used for performance analysis today. The most common calculations are based on the slope of the partition curve at the midpoint. Increased slopes correspond to enhanced separation performance, as a perfect separation exhibits a stepwise transition from 0 to 1 at the desired cut point, that is, an infinitely large slope. One common formulation of this slope, the Ecart Probable, Ep, is derived by evaluating the slope between the 25 and 75 percent recovery points:"

Jan 1, 2016

By M. Sears, G. S. Esterhuizen, Z. Khademian

According to the 2010-2019 Mine Safety and Health Administration (MSHA) accident report database, 91% of reported ground control accidents in U.S. longwall mines were caused by roof instability. Gateroads are subject to significant changes in loading conditions from the development to the longwall abutment loading phases. When combined with thinly bedded shale roof, found in many U.S. longwall coal mines, the design of efficient roof support becomes challenging. In previous work, the Bonded Block Method (BBM) modeling of roof by UDEC was validated against field extensometer measurements in a longwall gateroad entry roof at a 180-m depth of cover. The BBM was shown as capable of capturing delamination and buckling of shale roof, one of the main roof instability mechanisms in longwall mines. This paper presents the recent findings on the roof-support interaction using BBM models of the same longwall entry. The effects of cable bolts, roof bolt density, and strap support on potential roof instability are studied. These types of studies are difficult and costly to conduct in an operating mine. Results show how the contribution of bolts, straps, and cable bolts can be quantified using the BBM models. The study demonstrates the potential for BBM numerical models to help understand the complex roof and support system interactions and to assist with optimizing gateroad support systems.

Feb 1, 2023