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By S. D. Thompson, L. Adler

Several researchers in the last 20 years have developed computer simulation models for designing coal mine belt systems. A careful review of these reveals that each omitted or oversimplified important factors, especially in belt loading. To remedy this, the coal mine belt capacity simulator (CMBCS) was developed to include various types of probability distributions, delays, and longwall and continuous haulage. CMBCS is computer coded in FORTRAN and employs the Monte Carlo simulation technique. Basically, the model simulates the loading and corresponding flow of coal through a belt system. By recording spillage and belt stoppage statistics for the simulated flow, belt and surge bin capacities can be evaluated. A complete user's guide is available. The modeling and verification of CMBCS are briefly described, and its major advantages and disadvantages are explored.

Jan 1, 1987

By C. R. Stephan

There are a large number of facilities throughout the world which handle coal, such as preparation plants. Many other facilities use coal as a fuel, such as cement and lime factories. Although coal can be handled safely and can be an efficient fuel, there are explosion hazards which are accentuated as the particle size is reduced. Particle sizes of coal which can fuel a propagating explosion occur within thermal dryers, cyclones, baghouses, pulverized-fuel systems, grinding mills, and other process or conveyance equipment. This paper discusses how explosions can occur within these facilities.

Jan 1, 1998

By G. T. Adel

During the past decade, researchers at Virginia Polytechnic Institute and State University have worked to develop a novel flotation process for treating very fine particles. This process, which is now commonly known as [microbubble column flotation] (MCF), has been shown to be very effective in a number of applications related to fine coal processing. These applications include the retrofit of existing preparation plant circuits and the recovery of additional coal fines from refuse streams. In addition, work conducted under the sponsorship of the United States Department of Energy indicates that the MCF process is capable of producing superclean and ultraclean coals from many eastern U.S. coals. This paper describes some of the basic problems associated with fine particle flotation and the design and operational features of the MCF process used to minimize these problems. Also presented are the results of ongoing pilot- and field-testing programs.

Jan 1, 1989

By B. K. Baird, P. C. Satchwell

The application of cutoffs during and after pit optimization is examined for a lower-grade multi-metallic copper deposit. Pit optimization requires calculation of the net revenue associated with each mining block, incorporating parameters such as metal prices, grades and expected recoveries, mining and processing costs, smelting and refining charges, and penalty element and royalty charges. Sensitivity analysis during pit optimization reveals which of these parameters have a significant effect on the total contained resource tonnage and total contained non-discounted revenue in the optimized pit. The cumulative effect of changing several of the more significant parameters is investigated. Application of a copper cutoff grade to a block inside the optimized pit could result in the less than optimal extraction of the resource. A block with copper grade below the applied cutoff could be economic due to the presence of other metals. Conversely, a higher copper grade block may be sub-economic. The relative merits of applying a copper grade cutoff, “equivalent grade” cutoff and dollar value per ton cutoff to blocks inside the optimum pit are discussed.

Jan 1, 1999

By H. Polat, M. Polat, S. Chander

A high shear treatment step was observed to improve flotation of coal. The effect of high shear treatment (HST) was a strong function of coal rank, however. For the low rank coals the HST produced loose, open-structured agglomerates which decreased the entrapment of ash minerals. For the high rank coals, the high shear treatment promoted detachment of low-floating particles from the agglomerates that ordinarily formed in a flotation cell. The extent of agglomeration and detachment of particles from the agglomerates was a function of the amount of dodecane and coal rank. To obtain desired efficiency of separation ethylene-propylene oxide block co-polymers were used. The results showed that the HST-flotation technique increased the ash rejection considerably for both high and low rank coals, though the mechanisms were different.

Jan 1, 1995

By John Matthews

During 1982 and 1983, it became increasingly clear that North River No. 1 Mine would have to buy a set of replacement longwall shields. Despite extensive efforts to make improvements, the shields that were in place at that time were incapable of holding the roof. North River Energy had limited experience in specifying and acquiring longwall roof supports, but a great deal of experience with our conditions and needs. We there- fore compiled a shield evaluation method that uniquely responded to our situation. The resulting system emphasized teamwork among operating, maintenance and engineering personnel. The charge from management was threefold: select shields to support maximum expected loads, optimize face operations, and pay attention to detail. Final selection was made objectively, based on all available information. We chose a 5516 KN (620 tons) support with a minimum yield load density of 760 KN/m2 (7.9 tons/ft2). This paper reviews our process of specification, design, prototype testing, and fabrication, and offers some relevant suggestions.

Jan 1, 1986

By Lawrence J. Connelly

During the last decade, use of freeze conditioning agents (FCA) to ease unloading and handling of both run-of-mine and washed coal during periods of cold weather has become an accepted practice by the coal industry. This paper reviews some of the mechanical means of easing the handling of coal during periods of cold weather, as well as their use in conjunction with FCA's. Factors required to promote a successful cold weather handling program are also covered. Mechanisms by which FCA's function and the influence of various substrate characteristics on the ultimate response to freeze conditioning agent performance are discussed. A modified approach to freeze conditioning is presented.

Jan 1, 1986

By Kenneth S. Graham, S. C. Gambrell

A short term, simple roof bolt load cell which uses a birefringent (photoelastic) coating as its sensing element has been developed. The load cell is installed between the bearing plate and the nut/washer and measures the initial force after installation by the bolting machine. The load cell can be removed from the bolt and used again to measure initial force in another bolt if desired. Because temperature and humidity changes in the mine cause creep/relaxation of the coating and/or adhesive, the load cell is useful for accurately measuring force for a period of only two weeks after installation. Force in the bolt is determined by referring to a calibration curve for the load cell.

Jan 1, 1992

By Kim Lapakko

As part of a project funded by the US EPA, through the Western Governors' Association, the recent literature on the prediction of acid drainage from metal mine wastes was reviewed. Static tests such as Acid Base Accounting, Modified Acid Base Accounting, B. C. Research Initial Test, and APP:S Test attempt to quantify the total capacities for a mine waste to produce and consume acid. In kinetic tests (e.g. humidity cells, soxhlet extraction, elevated temperature oxidation, column tests, batch reactor tests, B. C. Research Confirmation Test) mine waste samples are subjected to oxidation and the resultant drainage pH is assumed to reflect that of mine wastes dissolving in the field. This paper summarizes information presented in the recent literature on static tests.

Jan 1, 1992

By Wu Chao, Wang Pinglong, Meng Tingrang

This paper discusses the research results of sulphide ore properties with respects on self-heating and the assessment techniques on mine spontaneous combustion for several mines of sulphide ores in China. A group of experimental devices for testing the chemical behaviour of sulphide minerals, the geological structures, the rate of oxygen absorption, the initial self-heating temperature, and the ignition point of ore samples, etc. are also described in detail. These methods have been proved to be effective by several sulphide mines which all have the history of spontaneous combustion of sulphide ores. INTRODUCTION A fire disaster from the spontaneous combustion of sulphide ores in a mine can produce large quantities of toxic gases and heat to pollute the working environment, lead to large economic losses and loss of human life, and even compell the mine to be closed. Some mines of copper, lead, zinc, tin and iron in China are of high content of sulphur. It is of great importance to evaluate the potential of spontaneous combustion of sulphide ores before beginning to design and mine the ore deposits. At present, the mechanism of spontaneous combustion accepted commonly is that sulphide ores undergo slow oxidation on exposure to moisture air at ambient temperature, with the evolution of heat, gases and moisture. The heat generated, if not dissipated, gives rise to an increase in the temperature of the sulphide ores. As the temperature of the sulphide ores rises, the rate of oxidation increases. If this is allowed to proceed unchecked it can eventually result in the ignition of the sulphide ores. For pyrite (FeS2), it reacts with oxygen and water according to the following equations.

Jan 1, 1993

By Brij M. Moudgil, Shoulian Zhu, J. L. Pinault

A new technique, prompt neutron activation probe (PNAP), for analyzing phosphate rock slurry in-situ was evaluated both in the laboratory and at the plant. The technique yielded a high precision in the analysis of Ca, Si and H using 252Cf source. Low accuracy of the direct measurement of P using 241Am/Be in the laboratory tests was attributed to the interference of rare earth elements present in the samples, particularly Gadolinium. No significant effect of variables such as solids loading, particle size distribution, and flotation reagents was observed on the probe performance. The probe can detect the compositional changes of the feed, tailings and the concentrate streams in the plant.

Jan 1, 1993

By P. Ollivier

The ore-processing plant of the Soremib mine Pour a (Burkina Faso) has now been in uninterrupted operation for 3 years. Ores from the oxidized and non-oxidized zones of the deposit are processed together in one flotation unit. About 60% of the gold is free and is recovered in a gravity processing unit. The residual gold in the flotation concentrate is processed on the spot by cyanidation and carbon-in-pulp.

Jan 1, 1998

By J. Mark Richardson

Modern mining operations are increasingly affected by complex economic factors. Broad and rapid fluctuations in metal prices, rising operating costs, socio-political trends and the inherent technical difficulties encountered in most operations, all can combine to quickly change once-profitable ventures into money-losing propositions. Accurate knowledge of metal inventories during all phases of an operation has become essential to wise management decision-making. This paper reviews key elements of metallurgical accounting: sampling theory, measurement technology and computerized data adjustment. Application of current technology to the reconciliation of a hypothetical operation is discussed.

Jan 1, 1991

By J. F. Cuderman

In situ experiments at the Department of Energy's Nevada Test Site (NTS) have extended the technology of propellant-based fracturing to include liquid- filled, uncased boreholes. Previous work had developed the technology for liquid-free, uncased wellbores. Test results show that fracturing behavior is considerably more complex in liquid- filled boreholes than in the liquid-free case. Compared to liquid-free boreholes, liquid-filled boreholes have faster pressure risetimes and lower peak pressures, large hydraulic-type fractures propagating several meters beyond the end of the test zone, numerous oscillations in the pressure history, and variable types of fracturing within a single test region. Multiple fracturing is initiated in the wellbore of a fluid-filled borehole when the proper propellant mixture is used but, unlike fluid-free wellbores where up to eight fractures propagate, only one to three hydraulic- and/or shear-type fractures propagate. Hydrodynamic effects involving liquid compression during borehole pressurization appear to be responsible for the differing phenomena observed in fluid- filled boreholes.

Jan 1, 1986

By Gordon E. Ager

A technique for the synthesis of mineral processing flowsheets from laboratory batch test data is described and examples of the application of the procedure are given. The procedure requires the collection of kinetic data, the optimization of the flotation time in each separation stage, then simulation of the material balance for a continuous circuit.

Jan 1, 1989

By Antti J. Niemi

Radioisotope tracers have so far been used for extraction of residence time distributions of flotation devices. They have also been proven applicable to evaluation of rate coefficients k of industrial flotation. It is now shown how values of k are scaled up on the basis of laboratory data on flotation and chemical conditioning, and of laboratory testing of samples from output of industrial conditioning vessel. Subsequently a model of conditioning and flotation is obtained which may be used for simulation and control of the steady state of the combined process. Discussion extends to modelling, simulation, CAD and opti- mization of flotation plants with re- circulation, and of ore dressing systems which consist of grinding and flotation plants.

Jan 1, 1990

By J. H. Calder, J. C. Hower

Three lithotypes of Phalen coal from Cape Breton County, Nova Scotia, Canada, were subjected to a modified Hardgrove grindability index (HGI) test. The testing scheme differed from conventional (ASTM D-409) Hardgrove testing by, in one case, repeating the test three times prior to removing the -200-mesh fine coal from the Hardgrove mill, and, in a second test, removing fines after each of three successive Hardgrove tests. Only the first stage of the latter testing scheme actually conforms to the standard HGI test. All processed samples were analyzed petrographically by a combined maceral/microlithotype analysis. The increase in the percentage of coal ground to -200 mesh increases through the 60- to 180-mesh fractions for each of the lithotypes for the following two apparent reasons. First, with progressive grinding, more of the oversize material is close to 200 mesh (75 µm), creating a "pool" of particles ready to be ground to -200 mesh, and, second, the removal of fines from the system at each step eases the grinding at the successive step. The fines retained system shows the influence of buffering of further grinding by the particles retained in the grinding mill. The Phalen lithotypes and the series of Central Appalachian coals, evaluated previously by Hower and Wild (1994), differ in that an increase in vitrite and a decrease in trimacerite is observed in successive -200-mesh fractions in two of the Phalen lithotypes. This is the opposite of the trend observed in the slightly lower-rank Central Appalachian coals.

Jan 1, 1998

By M. J. Scoble

There is no straightforward and systematic method for adequately measuring blast damage in on-going mining operations. This paper considers various techniques available for the measurement of blast damage, making particular reference to recent underground hardrock mine studies. This paper concludes by indicating the importance of understanding and accounting for geology and emphasizes the need for a robust damage-audit procedure.

Jan 1, 1997

By Sukumar Bandopadhyay

A present dominant problem is that of high downtime of the longwall shearer used in the coal production process. The means by which this problem can be overcome are many, but one of, the most important ones is that the-use of an expert system can reduce diagnostic and repair time. In this paper, a fault-diagnostic expert system model is presented. Specifically, the diagnostic architecture of the longwall shearer expert system and its use for diagnostic reasoning are discussed.

Jan 1, 1989

By M. F. Dibble

Borehole mining, as a viable concept for recovering deep sedimentary mineral resources, historically has been long on promise but short on results. Application of the technology seems best suited for recovery of Miocene phosphate resources on the East Coast of the US. These deposits are potentially enormous in scope and underlie sections of the coastal plain and the near offshore continental shelf. The landside portion of these deposits is generally too deep to mine using conventional open pit methods. Recovery of these minerals requires development of alternative mining systems. A significant proportion of the offshore resources appear to occur at depths below the practical limits of cutter suction dredges and may even exceed the limits of bucket ladder dredges. In most cases, these deposits are covered by overburden that must he removed and redeposited before the mineral section can be mined. The depth, thickness, composition of overburden and environmental sensitivity of a particular location would greatly impact mining system selection. It is probable that dredging would not be an environmentally acceptable mining method in many of the areas underlain by this phosphate rock. In cases such as these, new processes such as borehole mining must be evolved or the resource will remain undeveloped. A borehole mining test program, using an existing prototype borehole system, successfully extracted Miocene phosphate in northeast Florida in 1984-1985. The top of the main mineral zone was 80 m (261 ft) below the surface. Based on the results of this test program. plus subsequent laboratory testing and engineering studies, a new prototype borehole mining system was designed in 1986. This design incorporated several innovations of offering potentially higher productivity and lower power consumption than was achieved with the previous test unit. Economic restraints at that tine prevented the actual construction and testing of this new design.

Jan 1, 1992