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By F. A. Aplan, Richard R. Klimpel

This article discusses the role of mathematical optimization techniques as applied to the design and analysis of particulate processing plants. The emphasis will be placed on the macro engineering view of integrated multiple operation plants such as those that typically involve stages of size reduction, sol id-sol id separation, solids storage, chemical reactions involving sol ids, sol ids disposal, etc. The macro engineering view is chiefly concerned with balancing and optimizing the bigger picture of how various unit operations interact technical and economically with each other in an approximate sense rather than how a specific unit operation can be technically described and optimized in detail (micro engineering.)

Jan 1, 1991

By Neil Hillhouse

The Porgera gold district, like many other large gold deposits, has a long history of awareness, but only in the last five years has a geologic understanding of the district permitted the discovery of economically attractive gold reserves. The following sequence of events highlights the various significant steps in the evolution of the discovery process. The history of the district goes back about 50 years, and for several decades it was known only for its placer gold. Gradually, as gold became a more interesting metal, more and more attention was centered on the district. The sequence of events does not overstate the problems caused by isolation and climate, but the reader can imagine the difficulties inherent in such an area.

Jan 1, 1990

By Alissa Lockett, Chris D. Breeds

Central Water Integration Project (CWIP) Segment 5-1 is the most critical segment of a regional water supply project that transfers groundwater from Burleson County to northern San Antonio, replacing over 20% of that City’s water supply with a new source. CWIP Segment 5-1 included three tunnel reaches totaling 10,350-ft and 5 shafts that were constructed inside the City in an area known to contain large karst features. This paper describes site work used to investigate the alignment for karst features, manage potential environmental impacts, develop the contract package required for mitigation and the means and methods used to mitigate the large karst features that were encountered.

Dec 1, 2022

By Robert H. Scott

Developments during the past few years have brought coal-based composite fuels to commercial readiness. During the next few years, composite fuels will become available from a number of suppliers. Potential users must evaluate the combustion properties of these fuels to determine equipment and operating changes required for their use. Most work to date has been done with boiler applications. However, many potential non-boiler applications exist in the metals and minerals industry. These applications require specific evaluations appropriate for the processes involved.

Jan 1, 1982

By Giin-Fa Fuh, Sally A. Shoop

An instrumentation program was developed based on the results of an analytical study of the geomechanical effects of longer longwall face lengths. Boundary element simulations showed that longer face lengths can cause in- creased face convergence and an increase in the shear stresses in the immediate roof. Empirical design methods predict that longer faces will cause little effect on abutment stresses as long as the roof caving is well behaved. On this basis, a longwall face instrumentation program was designed with emphasis on the interaction between face support and ground response for optimizing face conditions. At a 600-foot (183 m) face, five midface shields and two headgate shields were monitored with vary- ing hydraulic pump pressure. The instrumentation included six convergence rods with linear potentiometers to measure canopy-to-toe convergence; fourteen pressure transducers to monitor leg pressures; and two portable data loggers. Similar instrumentation will be in- stalled on a 750-foot (229 m) face for comparison. The results from the 600-foot (183 m) face indicate that a ground reaction curve, as determined from the relationship between the sup- port set pressure and the roof convergence, can be used to optimize the support pressure to control convergence, the key element to ground stability in the face area.

Jan 1, 1986

By R. Kneisley, D. Conover, K. Haramy, K. Hanna

INTRODUCTION Coal mine entry intersections are high-risk areas for roof falls due to inherently wide roof spans, excessive stress, and variable intersection shapes resulting from breakthrough misalignments. Statistics from underground coal mines reveal that a high percentage of injuries occurs from roof and rib falls in entry intersections (Peng, 1980). The U.S. Department of the Interior, Bureau of Mines, is conducting a field research project to investigate failure modes surrounding underground coal mine entry intersections. The research objectives are to (1) develop a method to determine failure modes and stress-displacement relations around coal mine intersections and (2) develop engineering guidelines and empirical relationships for use in designing safer coal mine entry intersections. The basic approach to achieve the objectives is to instrument and monitor intersections before, during, and after intersection development in order to determine contributing parameters, such as in situ stresses, stress changes, strata movement, geology, physical properties, and mining sequence, that may influence the short- and long-term stability of the intersection and adjacent entries. This paper describes a rock mechanics instrumentation program, data analyses, and a comparison of two case studies conducted at two underground mines, designated as "A" and "B", in the Illinois Coal Basin. The instrumentation plans and data collected during development and long-term monitoring of four-way intersections and adjoining entries are presented. Data analyses of pre- and post-mining roof stress, pillar loading, strata movement, roof bolt loading, and geologic features are included. INTERSECTION FAILURE MECHANISM The region surrounding an entry intersection is characterized by different failure criteria than the region surrounding a single entry. Stresses induced during intersection development may result in a high incidence of roof and rib failures. Various numerical modeling techniques have been used to evaluate the failure modes surrounding intersections (Gercek, 1982; Chugh et al., 1975). Numerical modeling techniques include problems associated with the analysis of post-failure behavior, provision for different horizontal stresses (i.e., 01 f 021, and determination of inputs required for any non-elastic behavior. It seems likely that more sophisticated failure criteria, based on actual field data, are needed. The Bureau of Mines has conducted an extensive instrumentation program to investigate actual intersection failure mechanisms and to provide an improved understanding of stresses and deflections using beam and plate theories. Beam theory is not applicable to analyzing intersections (Wright et al., 1964); however, it can be used to explain roof deflection and failure (shear and flexure) of adjacent entries and to provide an improved understanding of stress changes and displacements as the entries, crosscuts, and intersection are developed (Hanna et al., 1985). Beam theory may be used for entries when the roof length is twice the width. When the length is less than twice the width (as in intersections), the roof must be analyzed as a three-dimensional problem, and stress and deflection calculations are based on flat plate theory (Adler and Sun, 1976). The confined-core theory (Wilson, 1972) hypothesizes that within a typical pillar, two regions exist: a confined-core region where the horizontal confining pressure is uniform and approximately equal to the overburden pressure, and a yield zone where the vertical pressure increases from nearly zero at the rib to a pressure peak at the boundary of the yield zone. The strength of coal in the yield zone ranges from nearly zero at the rib to nearly full strength at the confined core. The vertical stress in the confined core decreases from maximum at the yield zone boundary to the overburden pressure some distance into the pillar. Excavation of the adjoining entries

Jan 1, 1986

By J. A. Ryder

Compressed air is a relatively inefficient yet very convenient vehicle for transmitting mechanical energy. It is inefficient when compared to, say, hydraulic or electric energy systems since compressor and pneumatic machine efficiencies are quite low (in the range 20-65%) and reticulation losses can be quite high unless adequate pipe diameters are used to minimize friction drops. It is convenient in that capital and maintenance costs of pipes and machines are exceptionally low, the equipment is flexible and lightweight, the technological level is simple, the form of the energy supply is intrinsic- ally safe, and as an additional minor but psychologically important benefit, it provides a ready source of cooling and air supply for emergency use in deep hot mines. It is for these reasons that compressed air is a premier source of energy for many forms of underground equipment, in particular hand or rig-mounted rockdrills, some forms of rock- handling equipment, and a host of minor applications including agitators, small-lift pumps and temporary f am installations. In a typical S. African deep-level gold or platinum mine, compressed air generation accounts for 15% of the total mine electrical energy bill - more than is used for hoisting. In these mines it is not uncommon for over 100 km of underground compressed air piping to be installed, primarily to supply handheld rockdrills.

Jan 1, 1979

By E. Bonates

Dispatching systems have attracted considerable attention in the last years due to substantial gains in productivity achieved through their implementation. These systems will be extensively used in the future by mine operators as a means of optimizing productivity. This paper describes a computer simulation model designed to study the feasibility of continuously dispatching trucks in open-pit mines based on different operating procedures. The system developed is semi-automated and performs an active role by suggesting to the dispatcher the best assignment according to each specific circumstance. It is modeled based on an advance-clock increment to reduce computing time and allows the insertion of heuristic dispatching policies and equipment real-locations when breakdowns occur. Dispatching procedures taking into account long-term production objectives are considered in system development.

Jan 1, 1988

By D. Sinha

Mine investment decisions involve both objective and subjective criteria. The subjective criteria are efficiently decided by interaction with company experts. The Expert System approach can incorporate knowledge of experts and interact with conventional computer programs on mine evaluation. Artificial intelligence offers considerable opportunities in comprehensive mine investment decision making process.

Jan 1, 1998

By Alan C. Richter

Introduction The East-West Gateway Coordinating Council is an organization of local governments formed in 1965 to identify regional problems and to formulate policies, plans and programs to resolve them. The major goal of the Gateway Council is to improve the quality of life for the citizens of the St. Louis Region. While East-West Gateway Coordinating Council is the organization I represent and it only deals with the St. Louis Metropolitan Area, you will find one or more similar organizations in each of our nation's urbanized areas. As a result, for illustrative purposes, I will use my organization to portray what is happening nationwide. For example, in order to eliminate duplication, the Council reviews local applications for approximately 100 federally funded programs in such areas as highways, mass transit, parks, water treatment, and sewers before they can be sent to the appropriate funding agency. The Council's varied functions place it in a unique position of receiving more and more responsibility for developing strategies of implementation of various environmental regulations. This is due to the fact that environmental control is a relatively new field and we, as a country, are relatively inexperienced. The resulting regulations and guidelines will depend, to a great extent, on what the general public is willing to accept in terms of controls and what price they are willing to pay in terms of taxes and increased costs. Land Use: Growth vs No Growth This is perhaps the most encompassing environmental issue. We, as a nation, are beginning to realize that land is a limited natural resource and that the way we choose to use 'this resource affects many other aspects of our lives--whether we can catch edible fish in the Mississippi, how much we pay for sewer services, if we can swim in a

Jan 1, 1977

By P. D. Nora, M. G. Ranade

A statistically designed pot grate-kiln test program was conducted to determine the agglomeration process variables necessary for increasing the low temperature disintegration resistance (LTD) and reducibility (R40) of magnetite-based Empire acid pellets. The ASTM tumble index and compression strength were to be maintained at an acceptable level. Six process variables - bentonite addition level, preheat time and temperature, firing time and temperature, and cooling rate - were investigated within the constraints of the Empire plant. The bentonite addition level and firing temperature had the largest effect on pellet properties. The results of this program were verified during a plant trial. The target firing temperature at the Empire plant has been decreased for increasing the LTD and R40 of commercially produced Empire pellets.

Jan 1, 1987

By J. Lovering, H. Wilhelm, P. Siewert

Introduction The Afton property is located 290 km (180 miles) by air east-northeast from Vancouver and 14 km (8.7 miles) west of Kamloops, a city of 60,000 people, in south central British Columbia, Canada. The mine is adjacent to the Trans-Canada Highway at an elevation of 670 m (2198 ft) above sea level. The ore body is a porphyry copper deposit that has undergone supergene alteration. The major economic minerals in the supergene zone are native copper and chalcocite with chalcopyrite and bornite in the hypergene areas. The grade is 1% with an overall copper distribution - 70% native, 25% chalcocite, and 5% chalcopyrite with bornite and covellite. The ore also contains important but variable amounts of gold and silver. The mill was designed to treat 6350 t/d (7000 stpd). Semiautogenous grinding was selected to minimize capital cost and because of the expected high clay content of the ore, which would have caused problems in a conventional crushing and screening plant. Test work indicated that a recovery of 87% was possible in a circuit incorporating both flotation and gravity separation. Flowsheet Run-of-mine ore is crushed in a 1.06 x 1.65-m (3.5 x 5.4-ft) Allis Chalmers gyratory crusher set at 228.6 mm (9 in.), closed side setting. The surge pocket, below the crusher, is emptied by a Hydrastroke feeder onto number one conveyor, which discharges onto a 180,000-t (198,416-st) coarse ore stockpile. Six Hydrastroke feeders on two conveyors withdraw the crushed material from the bottom of the pile. These two conveyors, in turn, discharge onto the belt feeding the semiautogenous mill. The live storage in the stockpile is approximately 22,000 t (24,250 st), sufficient for three days' mill feed. Primary grinding is accomplished in an 8.5-m (28-ft) diam by 3.7-m (12-ft) long Koppers (Hardinge Cascade) mill (Fig. 1) containing a 10% ball charge and driven by a 4000-kW dc variable speed motor. The mill dis¬charge is pumped by a 10 x 12 G.I.W. pump to a 1.22 x 4.88-m (4 x 16-ft) stationary screen sloped at 20°. Screen oversize returns to the semiautogenous mill (SAM), and the undersize flows by gravity to the ball mill discharge pump box. Secondary grinding is performed in a 5-m (16.4-ft) diam by 8.84-m (29-ft) Koppers overflow ball mill driven by a 3430-kW synchronous motor through an air clutch. The mill is in closed circuit with a Krebs Cyclopac containing 10 635-mm (25-in.) cyclones and the cyclone overflow, at 35% solids and 65% to 70% -200 mesh, is flotation feed. In order to limit the buildup of native copper, circulating in the secondary grinding circuit, a portion of the underflow from the cyclones is processed in a circuit containing screens, cyclones, and shaking tables to produce a finished metallic copper concentrate. Primary mill variable speed drive The overall waste to ore ratio at Afton was 4.5:1. The mining was to be done with only three shovels, which meant that it was highly unlikely that more than one of them would be in ore at any one time. The resulting inability to blend the mill feed made it impossible to prevent wide swings in the grade and grindability. The variable speed do drive motor installed on the semiautogenous mill was selected because of the extreme variability of the Afton ore body. This variability has persisted throughout the lifetime of the mine. There are times, however, when due to ore conditions, the mill is operated at full speed (78% of critical) for extended periods of several shifts duration. There are other times when the mill speed may be changed several times in a 12-hour shift due to changing ore conditions. When ore is processed that contains a fairly large proportion of fine native copper, the primary mill speed and, consequently, the tonnage may be reduced to improve the secondary grind and to maintain an acceptable grind and recovery. High clay ores require less mill speed and more dilute grinding densities. In the latter case, the slower primary mill speed also helps to minimize damage to the mill liners. Approximately 57% of the time the mill operates between 90% and 100% of full speed or between 71% and 78% of critical. The variable speed is also used for inching during mill relines.

Jan 1, 1987

By W. Irwin

Global warming hitherto viewed as a distant threat to the environment, is now the subject of fierce goo-political debate. The debate centres around the time frame required to achieve environmental compliance, and the cost implications of meeting that objective. Since coal is the fuel of choice for power generation, the priority objective of energy producers is the pursuit of environmental protection measures that allow coal to be burned without any attendant negative impact on the environment. From an environmental point of view, public attention is today firmly focused on the impact that all industrial activity has on the environment, and coal is singled out from other fossil fuels as being the product of an inefficient smokestack industry. Despite coal's poor public image it is unrealistic to suggest as some do, that use of this fossil fuel as a primary energy source should be drastically curtailed. Coal which already generates about 35% of the world's electricity is continuing to increase its share of this rapidly expanding market, and to argue against its use is flying in the face of reality. However, changes are required in the way coal is used in some of the new clean coal technologies, since many include advanced methods of combustion. Indeed changes in the way coal is used is a vital link to the future of coal as a primary source of energy, and increased coal utilization will be directly linked to changes in its use. Discussion of various issues that affect coal utilization are the focus of this paper.

Jan 1, 1998

By Panlop Huttagosol

The use of computer models to design ultimate pit limit of an open pit mine during its feasibility study has become an emphasized procedure in mining. It is a normal practice in open pit mine design to generate the most profitable final pit limit. The limitations of designing this optimal pit limit have been the requirement of significant computing efforts as well as the use of complicated operations research techniques. In an attempt to describe a computer method that has an easy conceptualization and is able to provide a precise and desirable solution, a new technique is developed. The ultimate pit limit problem is formulated as a large scale transportation problem. The formulation is based on the use of a three dimensional block model to represent an ore body and surrounding materials. The solution technique is developed through solving the dual system of the formulated problem by using the adapted simplex algorithm of linear programming. The implementation on given case studies demonstrates that the new method is capable of providing an optimum pit value. The computing effort required by the algorithm is still the main constraint in solving a large scale problem. The technique provides open pit mine planners with an alternative tool in using a commercial linear programming software which is capable of solving a general transportation problem. The selected software must be able to handle a large scale problem, and it needs an additional effort td formulate the problem and transform a result into the ultimate pit limit solution.

Jan 1, 1992

By D. W. Wu, M. T. Haque

A novel impedance probe was commissioned specifically for capturing fast dynamic information about filtration processes. It provides an attractive alternative to more complex measurement techniques in situations where the slurry system is primarily one-dimensional. The probe can monitor mudline, slurry densification and drainage. Dynamic variations in cake permeability are obtained by combining dynamic mudline information obtained with the probe and filtrate rate data derived from a leaf test apparatus. The measurements are reviewed in relation to micro structural measurements obtained on iron ore filter cakes. The practical significance of these measurements for optimization of the filtration process is discussed.

Jan 1, 2002

By Craig J. Nelsen, David A. Smith

In 1987, LAC Minerals (USA), Inc. conducted a high resolution helicopter electromagnetic (EM) and magnetic geophysical survey on the Ortiz Mine Grant, New Mexico. The primary purpose of this survey was to assist in geologic mapping of a major structural zone, the Tijeras-Canoncito Fault System (TCFS). This structure is a very important ore- controlling feature in the area. Geophysical signatures over known deposits was a secondary goal of the survey, but direct detection of mineralization was not anticipated. The TCFS was revealed to be a complex, branching and anastomosing system of faults which locally form the bounding structures of a graben. The geophysical survey guided subsequent geologic mapping by redirecting field investigations, and geophysically redefining some features which previously had been only partly defined.

Jan 1, 1989

By B. Cavender

Investments in new technology are often intended to improve the production or cost performance of existing operations. The economics used to justify these projects can be flawed, however, if they do not adequately consider the potential benefits of the alterative: the fully optimized use of the facility's present equipment and personnel. While new technology can be effective, dramatic improvements in production performance can also be achieved through the rigorous application of standard industrial engineering and operations management practices. An intermediate approach may also be effective: many basic improvements In the mine or plant necessary to support new technology will be equally effective when implemented for the facility's present operators. Firms who optimize their present operations are able to save the capital and avoid the risk associated with new technology. These firms will also be able to capitalize more quickly on new technology when it is implemented.

Jan 1, 1999

By Gilman Y. Murray

The problems connected with the development of economically acceptable water supplies in arid regions are discussed. The techniques for capture and retention of runoff from infrequent desert storms are described and the major factors involved are emphasized. The exploration and planning for a typical water development in southwest United States is described, including an analysis of capital and operating costs for the proposed system.

Jan 1, 1963

By SONGHE WANG, YI XUE, PENG HOU, CAIHUI ZHU, XUANYE JIAO, Feng Gao

Coalbed methane development is an important way to effectively realize a source of clean energy and reduce emissions of carbon dioxide and other gases. However, due to the low permeability of coal seams, the development of coalbed methane in China has encountered substantial barriers. Protective layer mining can efficiently minimize in situ stress and increase coal seam permeability, thus improving gas drainage and avoiding gas disasters. This study analyzed the characteristics of gas migration and the change in permeability during the in situ stress releasing process through experiments and numerical simulation to study the gas drainage effect of a coal mine in an unloaded coal seam under specific geological conditions. First, a stress–strain-seepage coupled test of coal was carried out, and the evolution features of coal permeability during stress loading and unloading processes were investigated. Second, experimental results were used to develop a mathematical model of coal seepage under mining unloading conditions. Finally, a numerical model was developed based on the real geological conditions of the Wulan coal mine to explore the characteristics of in situ stress release and permeability evolution, as well as the gas drainage process in an unloaded coal seam. By combining protective layer mining and gas drainage technology, the risk of gas outburst is significantly reduced.

Oct 1, 2022

By T. X. Ren, J. S. Edwards

Although much work has been carried out in order to understand the mechanism of spontaneous combustion and hence minimise its potential risk, the spontaneous combustion of coal continues to be a problem in coal mining. The Department of Mineral Resources Engineering of Nottingham University has been active in conducting fundamental research into the problem of spontaneous combustion of coal. For years standardised adiabatic oxidation tests have been used to identify coals and other carbonaceous materials liable to spontaneous combustion. Recently the apparatus has been computerised and coupled with an expert system known as ESSH to evaluate the potential of self-heating of coal on the basis of intrinsic coal properties, geological settings and mining techniques. A numerical model has been developed to study the aerodynamics of airflow in the wastes of longwall coal faces. The Computational Fluid Dynamics approach is being explored to simulate airflow behaviour and nitrogen inertisation processes within the goaf. Such a model would be used in locating the areas most liable to spontaneous combustion and improving the utilisation of nitrogen. It would also be possible to determine the most likely path ways of combustion/heating products so as to provide an indication of the most appropriate locations for fire detectors.

Jan 1, 1997