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By D. R. Willmer

An understanding of how health and safety management systems (HSMS) reduce worksite injuries, illnesses and fatalities may be gained in studying the behaviors of health and safety leaders. These leaders bear the accountability for identifying, understanding and managing the risks of a mining operation. More importantly, they have to transfer this knowledge of perception, recognition and response to risks in the mining environment to their workers. The leaders’ efforts to build and maintain a mining operation’s workforce that consistently executes safe work practices may be captured through more than just lagging indicators of health and safety performance. This exploratory study interviewed six leaders in occupations such as site-level safety supervisors, mine superintendents and/or general managers at surface and underground stone, sand and gravel and metal/nonmetal mine sites throughout the United States, with employee populations ranging from 40 to 175. In exploring leaders’ perspectives on how they systematically manage health and safety, examples such as approaches to task training, handling near-miss incidents, identifying future leaders and providing workers with feedback offer insights into how leaders translate their knowledge and management of site-level risks to others.

Jan 1, 2018

By D. R. Willmer

An understanding of how health and safety management systems (HSMS) reduce worksite injuries, illnesses and fatalities may be gained in studying the behaviors of health and safety leaders. These leaders bear the accountability for identifying, understanding and managing the risks of a mining operation. More importantly, they have to transfer this knowledge of perception, recognition and response to risks in the mining environment to their workers. The leaders’ efforts to build and maintain a mining operation’s workforce that consistently executes safe work practices may be captured through more than just lagging indicators of health and safety performance. This exploratory study interviewed six leaders in occupations such as site-level safety supervisors, mine superintendents and/or general managers at surface and underground stone, sand and gravel and metal/nonmetal mine sites throughout the United States, with employee populations ranging from 40 to 175. In exploring leaders’ perspectives on how they systematically manage health and safety, examples such as approaches to task training, handling near-miss incidents, identifying future leaders and providing workers with feedback offer insights into how leaders translate their knowledge and management of site-level risks to others.

Jan 1, 2017

By K. H. Boss

In modern iron pelletizing plants fuel consumption has been optimized to such an extent that only minor savings can be expected in the future. Inspite of this fact, different process parameters were studied with a mathematical model and firing tests. The influence on fuel consumption and productivity was established. Furthermore, the adoption of simplified firing patterns was investigated, in particular for coal firing. In view of high costs of oil and natural gas, only substitution of these fuels by coal can substantially reduce production costs. In existing plants partial replacement of oil and gas can be achieved by addition of coal to the iron ore feed and by firing the pellets with pulverized coal. Two systems have been developed for the Lurgi- Dravo travelling grate process which enables coal to completely replace oil or gas. This paper describes in the first part the potentials for fuel savings available in the Lurgi-Dravo process. In the second part, different techniques for the use of coal as fuel in iron or pelletizing plants and in particular the recently developed Lurgi Multistage Coal Injection and Combustion Process (LMC) are discussed. Combined with the LMC process, a wide variety of iron ores and coals - also with high ash contents - can be used in the Lurgi-Dravo travelling grate process.

Jan 1, 1983

After World War I the character of my mining life changed completely. Before then adventure had been almost continuous but after the war there was lots of staying in one place, almost routine, between adventures. This was fortunate, as the life of a mining engineer is a wandering one at best, and it makes being married and raising a family a dubious enterprise. It would have been quite out of the question with the life I led before I got married at the end of the war The new sort of life made the "beaconing of adventure" intermittent. There were often long stays at home between wanderings which was fortunate as it changed the continuity of these memories. I must briefly summarize accounts of the more or less routine periods and concentrate on the occasional exciting episodes between. After a long visit with friends in Berkeley, Dorothy and I left for Arizona and three days at the Grand Canyon that were nearly too much for both of us. One beautiful day we started a short walk down the Bright Angel Trail. It was such a lovely bracing day that we kept on walking and enjoying the views until, just after noon, we reached the Colorado River. We were the only ones in sight so to enjoy the sunshine to the full we both had a good swim in the swiftly flowing river. So far, everything was wonderful. But when we started to climb back up the trail, rising nearly 6000 ft in ten miles we soon found that we had counted too much on our youth and endurance. We had to rest every few hundred feet and it seemed as though we would never reach the top. It was eight o'clock in the evening when we finally staggered into our room and collapsed. On the way to the Canyon I had seen John Greenway and Dr. Ricketts in Santa Barbara and they had little idea what would happen to them or to me. Before resuming his position as general manager of Calumet and Arizona and New Cornelia, Greenway must recover from the effects of the gas he had suffered in the war. Dr. Ricketts

Jan 1, 1976

By J. Herbst, J. Groppo, A. Noble, R. Q. Honaker

"Coal and coal byproducts produced annually contain a sufficient amount of rare earth elements (REEs) to meet current U.S. demand. The REEs exist in the form of minerals, ion-adsorbed elements associated with clays, and chemically bonded elements within the organic coal matrix or host mineral. Researchers at three universities collaborated to evaluate the effectiveness of existing physical and chemical concentration processes for the recovery of the REEs. The efforts found that physical separation processes can increase the total REE content in the thickener underflow material collected from a Central Appalachian coal cleaning facility from around 300 ppm to values greater than 17,500 ppm on an ash basis. Leaching followed by solvent extraction was found to be the most effective to recover the REEs from coarse middlings materials collected from multiple coal basins, as indicated by recovery values exceeding 80 percent. Based on material characterization data and process evaluations conducted for several potential feed coal sources, economic recovery of the REEs will require byproduct production of both clean coal and REE concentrate using a process flowsheet that is unique for each source. IntroductionRecent studies initiated by the National Energy Technology Laboratory showed that U.S. coals contain significant amounts of rare earth elements (REEs), suggesting that rare earth minerals (REMs) and/or REEs can be produced as byproducts (Ekmann, 2012). According to the report, the richest source of REEs is the Central Appalachian coal. At present, there are 208 coal preparation plants located in the region consisting of areas within the states of West Virginia, Kentucky, Pennsylvania, Virginia, Alabama and Tennessee, with a total capacity of 166,495 t/h, or more than 1 Gt/y (Fiscor, 2014). If only a portion of these plants are retrofitted with advanced separation processes, the U.S. coal industry would become a significant producer of REE concentrates as byproducts. An inherent advantage of becoming a byproduct producer of REEs is that no mining cost needs to be part of the production cost."

Jan 1, 2017

By S. Lu

The particle-bubble attachment and the rupture of formed aggregates in flotation cell were investigated in terms of turbulent regime. It was found that the particle-bubble collision rate is closely correlated to the energy barrier between particles and bubbles, and no adhesion takes place for the hydrophilic particle-bubble system due to the introduced ?capture efficiency? f(a) being zero. The values of an especially defined Weber number, i.e. the ratios of turbulent stress to aggregate strength in the inertial subrange of turbulence were estimated, the results showed that the detachment of a particle from a bubble involved in an aggregate is mainly caused by the turbulent stress only in the impeller zone, no bubble splitting occurs both in the impeller zone and in the bulk zone.

Jan 1, 1993

By G. Barbery

In Mineral Processing, the objective of most processes is the separation of mixtures of minerals, which are originally associated in composite particles. Feed preparation processes grinding for instance, which take place before beneficiation or separation processes do not usually break particles at the boundary between mineral phases. They produce composite ("middlings") as well as liberated particle. It is therefore necessary, in a particulate system, to determine the proportion of particles which are liberated as well as, ideally, the size distribution of minerals which remain associated in composite particles. Up to now, there has been a lack of experimental techniques to characterize completely composite particulate systems. Heavy liquid separation which is commonly used to obtain information of this type can only be applied to simple binary cases for which one mineral has a low density (lower than e.g 2.8 ). The technique which is proposed in this paper involves the measurement of parameters on polished sections of particles mounted in a matrix, and the use of mathematical transformations to reconstruct in three-dimensions the information obtained from these measurements .

Jan 1, 1977

By Cengiz Karagüzel, Ömer Canıeren

The mobility of gold and silver metals from refractory ores is very low due to free metal ions in their bodies that bind the transportable and free metal molecules or they are encapsulated in minerals such as sulfides, arsenosulfides, carbonaceous, and clayey materials which make it difficult to extract them. As known from the literature, the enrichment of oxide refractory gold, silver ores, Ag, and Au-rich flotation concentrated from sulfur refractory ores can be leached in the chloride-hypochlorite solutions. In this work, the leaching approach was studied to extract silver ions from refractory ores in the presence of hypochlorite media under high pressure. The mineralogical and scanning electron microscopy analysis of the sample indicated that the silver was encapsulated in barite and quartz minerals in fine sizes. In order to obtain the optimum leaching conditions for the silver ore, the effects of several parameters, namely, temperature, leaching time, NaCl and NaOCl concentration, solid ratio, and particle size on the leaching recovery were investigated in detail. The leaching experiments showed that the highest silver recovery of 62.35% was obtained under the following conditions: temperature of 150 °C, oxygen pressure of 1800 kPa, leaching time of 2 h, concentrations of 2 mol/dm3 and 0.4 mol/dm3 for NaCl and NaOCl, respectively, the solid ratio of 30%, and particle size (d80) 15 μm. The results obtained from this study indicated that the enrichment of refractory silver ores to extract the silver encapsulated in barite and quartz minerals could be possible in the chlorite-hypochlorite under high pressure, a relatively shorter leaching time compared to conventional cyanide leaching.

Jan 28, 2021

By Kwangmin Kim, Junnhyeok Park

In the hard-rock mining industry, the generation of fines during blasting is an important issue because it has a significant effect on production processes. Although various approaches have been used to estimate fines generation in recent decades, as a practical matter, measuring the amount of fines is nearly impossible given the technical limitations and the scale of mine blasts. In this study, a dynamic PPV damagemodel was developed and applied to predict fines generation as a result of blasting. This modified version of the crushed zone model (CZM) considers dynamic rock properties and peak particle velocity (PPV), which represents the induced stress in blasting. Dynamic rock-fracturing tests were conducted using a split Hopkinson pressure bar (SHPB) to determine the parameters that represent the relationships between rock strength and strain rate as well as the relationships between fines amount and strain rate in the model. A case study was conducted that entailed determining the radius of the crushed zone for given blast designs and rock properties and then measuring the fines amount within this crushed zone. This case study indicated that the dynamic PPV model can provide a rough estimate of fines generation for given dynamic rock properties and blast design parameters and that this method has the potential to be a useful indicator, or index, of fines generation.

May 16, 2020

By J. D. Miller, C. L. Lin

From mine to mill, the 3D characterization of particles ranging in size from meters to micrometers is now possible. A brief review of X-ray tomography for mineral processing is given with recent advances considered, such as high-speed scanning and image analysis procedures to describe important particle properties, including size, shape and composition. Considering these new 3D characterization tools, applications in mineral processing are discussed for high-resolution X-ray microtomography (HRXMT) laboratory analysis of particles ranging from 20 mm to 5 μm, with a voxel resolution of about 1 μm, including (1) multiphase particle characterization by HRXMT and comparison with scanning electron microscopy (SEM), (2) particle damage state as a result of blasting/comminution, (3) liberation characterization to describe expected separation efficiency, (4) exposed grain surface area analysis to explain the flotation of locked particles, and (5) floc size, shape and water content for polymer-induced flocculation. Finally, applications in mineral processing for plant-site analysis using high-speed X-ray computed tomography (HSXCT) are examined, including, for example, coal washability analysis, the analysis of crusher plant products, and the analysis of pebble phosphate products from central Florida. Scanning rates on the order of 1 kg/min for particle sizes ranging from 150 mm to 1 mm are possible, with a voxel resolution of about 100 μm. For coarse particles smaller than 5 to 10 mm, high scanning rates of more than 300 t/h may be possible at a voxel resolution of about 1 mm.

By Patrizia Pereyra, M. Guzman, C. Toledo, J. A. Rau, A. Ruiz

The use of mining tailings-based geopolymer binder as a substitute for cement can be an interesting alternative to the problem of final disposing of large volumes of them. Indeed, mining tailings have a high silica content, which makes them suitable for geopolymerization. The tailings samples contain Cu, Pb, Zn, As, Sb, Cd and Bi, mainly. X-ray diffraction results show that the tailings are composed of quartz, SiO2 (81%). Geopolymerized tailing samples (GTPS) were obtained by varying the ratio of SiO2/ Al2O3 and SiO2/NaOH. The compressive strength of the GTPS varied between 2 MPa and 8 MPa. The electrical conductivity in the leaching tests varies between 13.91– 16.11 mS/cm2 indicating that ions are present in the solution. However, the pH = 10.5 indicates that acidity is not being generated. The element that mostly leaches is iron. The highest percentage of leaching is observed for cadmium (69%) and chromium (93%). The concentrations of elements are under the maximum permissible limits for water according to the Peruvian legislation. However, mass transfer leach tests and immersion leach tests must be realized.

Feb 1, 2024

By J. F. Hutwelker

A pilot plant was constructed and operated to investigate the column flotation of 20 x 200 mesh North Carolina phosphate ore, using high throughput, high solids operating conditions developed at the NCSU Minerals Research Laboratory. Flotation was performed at 45% solids in a 9.5 cm (3.75 in.) diameter by 2.26 m (7.4 ft.) tall column at throughputs of 19.1 t/hr/m2 (2.0 stph/ft2) and 31.7 t/hr/m2 (3.3 stph/ft2). Recoveries in excess of 98% of the phosphate value were obtained at the lower throughput -- while obtaining concentrate grades containing over 28% P205 (61.2% BPL) at that recovery. Recoveries of about 95% of the phosphate value were obtained at the higher throughput, while making a concentrate averaging 27.6% P209 (60.3% BPL). In addition, a better understanding of the variables governing the column flotation of coarse nonmetallic minerals was gained. Low air flow rates adversely affected concentrate grade at the lower throughput. At the higher throughput, phosphate recovery decreased at an elevated air flow rate. An unexpected result of the study was the effect that frother type had upon phosphate metallurgy. Use of Nottingham Econofroth 925 provided better flotation selectivity than American Cyanamid F-65 at the low throughput. This is significant since the high' throughput tests were conducted with F-65 exclusively. It is reasonable to expect further improvement in high throughput performance when the optimal frother type and dosage are determined.

Jan 1, 1993

By Noriyuki Fujii

It is no need to say that exploitation of industrial minerals has a close relation to development of the industries related. In the first stage, a small scale manufactures were initiated in areas producing some main raw material minerals. China and cement manufactures, for example, were established depending on the local occurrence of raw materials such as kaolin and limestone without exception. That is, the industrial development is greatly influenced by the local production of the raw materials in the stage. With the development of industrial technology, various kinds of raw material minerals are explored to meet the demands of industries in the second stage. New materials become indispensable, and low-grade raw material minerals, which were left as useless, are developed as useful materials. In the stage, the development of raw material minerals is accelerated by that of industrial technology related. However, industries mainly rely on domestic production of the min raw material minerals.

Jan 1, 1981

By Osvaldo A. Bascur

Standards and Technology for bringing information at the desktop has greatly evolved in recent years. The benefits to be realized depend on how these new tools are embraced at the performer level. A key operating challenge is to ensure collective effort is geared towards the most efficient achievement of identified operating and corporate objectives. Presentation, application and data repository modular software are emerging in successful client server applications. The industrial desktop emerges as the new tool for continuous improvement and innovation in industrial operations. Here, process information, reliability maintenance, process simulation, production schedules, performance monitoring are integrated using Microsoft enabling tools at the desktop. A workflow model is presented to assist in implementing a strategic information system in metallurgical plants.

Jan 1, 1996

By Jay F. Colinet

Coal workers’ pneumoconiosis (CWP), commonly known as black lung, is caused by the inhalation of respirable coal mine dust and is a disabling and potentially fatal lung disease with no cure. Historically, CWP has taken a tremendous human and financial toll in the US coal mining industry. Recent health surveillance data indicates that CWP continues to occur at elevated levels. Respirable coal dust exposure must be controlled to prevent the development of CWP. The Pittsburgh Mining Research Division of the National Institute for Occupational Safety and Health (NIOSH) conducts laboratory and mine-site research to identify control technologies that can be used to successfully reduce respirable dust levels. Various technologies, using multiple methods of control, can be applied in order to reduce dust levels. An overview ofCWP’s impact and a general methodology for controlling respirable dust in underground coal mines are discussed in this paper.

Jul 30, 2020

By R. Bryce, T. J. Doughty, K. Stoll

Sulfate-impacted mine waters are under regulatory scrutiny to reduce total dissolved solids (TDS). There are several options to reduce TDS. One option is transforming the soluble sulfate into insoluble ettringite. The Water Company LLC (TWC) patented a process for sulfate removal through ettringite formation by reacting directly with metallic aluminum. Freeport-McMoRan (FMI) and TWC have collaborated to design, build and operate a 10-gallon-per-minute (gpm) ettringite pilot plant to establish reagent consumption, plant availability and full-scale design criteria. Using metallic aluminum as the primary aluminum source for ettringite precipitation eliminates the addition of other ions, resulting in significant demineralization. The pilot plant achieved greater than 98% water recovery, greater than 90% reagent efficiencies and maintained reactor sulfate levels below 250ppm. BACKGROUND Ettringite is a hydrated calcium, aluminum, sulfate mineral with the following formula: Sulfate-impacted mine waters are under regulatory scrutiny to reduce total dissolved solids (TDS). There are several options to reduce TDS. One option is transforming the soluble sulfate into insoluble ettringite. The Water Company LLC (TWC) patented a process for sulfate removal through ettringite formation by reacting directly with metallic aluminum. Freeport-McMoRan (FMI) and TWC have collaborated to design, build and operate a 10-gallon-per-minute (gpm) ettringite pilot plant to establish reagent consumption, plant availability and full-scale design criteria. Using metallic aluminum as the primary aluminum source for ettringite precipitation eliminates the addition of other ions, resulting in significant demineralization. The pilot plant achieved greater than 98% water recovery, greater than 90% reagent efficiencies and maintained reactor sulfate levels below 250ppm. BACKGROUND Ettringite is a hydrated calcium, aluminum, sulfate mineral with the following formula: Ca6Al2(SO4)3(OH)12•26H2O Ettringite readily precipitates in high pH water and by doing so, removes sulfate from impacted waters. The SAVMIN process, piloted in South Africa, is one method to produce ettringite. In this process, aluminum hydroxide is the aluminum source. The Cost Effective Sulfate Removal (CESR) process is similar to SAVMIN, but uses a proprietary aluminum source instead of aluminum hydroxide. Outotec and Veolia also have their own versions of the process using their specialized process equipment. TWC patented a version of ettringite precipitation using metallic aluminum as the aluminum source for ettringite formation. The benefit of using aluminum metal is that no additional ions are added to the process. At high pH, the raw aluminum corrodes in water causing hydrogen gas generation as the water is chemically reduced. This reaction is shown below:

Jan 1, 2019

By Xiaobo Zhang, Panshi Xie, Xiaobo Wu, Ding Lang, Jiandong Yu, Yongping Wu, Kun Feng

In a fully mechanized top coal caving mining process, the mechanical properties of the top coal deteriorate constantly, and the stability of the support is determined by the boundary position of the top coal entering the limit equilibrium state. Top coal flaking occurs more easily along the advancing direction owing to an increase in the distance of the boundary from the wall. Moreover, the strength of the coal seam is an important factor that determines the boundary position. The equation of the top coal limit equilibrium zone boundary, used in fully mechanized top coal caving mining, was determined based on the limit equilibrium theory, continuum damage mechanics, and the Hoek–Brown rock empirical strength criterion. Using the RFPA3D and UDEC numerical analysis methods, the effect of top coal strength on the mechanical behavior during the mining process was determined; and the space–time relationship between the top coal deformation failure, damage evolution, and boundary of the limit equilibrium zone was established. The results revealed that when the coal mass entered the limit equilibrium zone, accelerated crack development, accelerated damage, and axial unloading occurred. Moreover, an increase in the coal seam strength caused the boundary of the top coal limit equilibrium zone to be closer to the wall. By comparing the numerical results with the theoretical results, the overall trend was found to be consistent, allowing the verification of the rationality and reliability of the determination equation of the boundary position of the limit equilibrium zone.

Sep 21, 2021

By R. J. Matetic, J. Noll, C. Zhou, J. DuCarme, M. Reyes, J. Srednicki

"In April 2016, the U.S. Mine Safety and Health Administration (MSHA) began requiring the use of continuous personal dust monitors to monitor and measure respirable mine dust exposures to underground coal miners. Mines are currently using the PDM3700 personal dust monitor to comply with this regulation. After the PDM3700’s implementation, mine operators discovered that it interfered with proximity detection systems, thus exposing miners to potential striking and pinning hazards from continuous mining machines. Besides the PDM3700, other electronic devices were also previously reported to interfere with proximity detection systems. MSHA sought the aid of the U.S. National Institute for Occupational Safety and Health (NIOSH) and mining industry stakeholders to determine how the PDM3700 and some other electronic devices and proximity detection systems interact with each other. Accordingly, NIOSH investigated existing standards, developed test protocols, designed experiments and conducted laboratory evaluations. Some interferences were observed to be caused by electromagnetic interference from some electronic devices, including the PDM3700. Results showed that there was no significant interference when the PDM3700, as well as other electronic devices, and the miner-wearable component of the proximity detection system were separated by distances of 15 cm (6 in.) or greater. In the present study, it was found that the PDM3700 and the personal alarm device needed to be at least 15 cm (6 in.) apart in order for them to be used simultaneously and reduce potential interference. IntroductionUnderground coal miners are exposed on a daily basis to a variety of hazards, such as coal dust exposures, high noise levels, roof and rib falls, potential for fires and explosions, and operating and working with heavy machinery. One of the hazardous jobs is that of operating or working near a continuous mining machine. According to U.S. Mine Safety and Health Administration (MSHA) statistics, 44 miners had been fatally struck or pinned by a continuous mining machine since 1984. In an effort to prevent future striking and pinning fatalities from occurring, proximity detection systems have been developed and are required on all operating continuous mining machines in underground coal mines, with the exception of full-face continuous mining machines, by 2018 (MSHA, 2015a)."

Jan 5, 2018

By CASSANDRA L. HOEBBEL, Emily J. Haas, MARGARET E. RYAN

Researchers examined datasets from two separate studies that measured common demographic variables but different safety performance outcome variables. Of specific interest was how types of experience might relate to workers’ preparedness to effectively mitigate or respond to both routine and nonroutine risk in the mining industry. The results suggest that individual factors such as length of job, industry, and mine experience are predictive of routine safety performance — as measured by self-reported proactive and compliant safety behaviors — and/or nonroutine safety performance — as measured by perceived competence in self-escape knowledge, skills and abilities (KSAs) — in significant and sometimes unexpected ways.

By S. Dubnewych, S. Kieffer, M. T. McRae, R. R. Redd

The seismic vulnerability of the existing outlet tower at Lake Mathews reservoir, located in Riverside County, California, necessitated the design of a new outlet facility to assure serviceability of the facility following a major earthquake. The components of the proposed facility include: a new outlet tower; a shaft; a new outlet tunnel; an approach channel that will be excavated underwater; and two short tunnels that will connect the new outlet tunnel to the existing outlet tunnel via the shaft. As the new facilities will be constructed while the reservoir is in operation, a cofferdam will be constructed around the site of the new outlet tower. The design for the underground facilities used a combination of empirical methods; limit equilibrium analyses, including displacement-based pseudo-static analyses for dynamic loading conditions; and numerical analyses. This paper outlines the design methodology used to develop an innovative design for the facilities which can be constructed within the time frame required by the operational schedule of the reservoir and existing outlet facility.

Jan 1, 1999