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By P. K. Muduli

The number and the type of trucks and shovels are two important factors in determining the optimal design parameters of an open-pit mining system. Characteristics of trucks' arrival and service-time distributions determine the performance measures of a truck-shovel system when it is modeled as a closed queuing network. In all of the previous analytical queuing studies of truck-shovel systems, trucks are assumed to be identical with respect to their arrival and service-time distributions. This assumption, although desirable for reducing computational difficulties, causes either underestimation or overestimation of the performance measures depending on the number and type of equipment used in the model. The relative error in performance measures could be significant when the number of different types of trucks and shovels is large. In this paper an analytical method is proposed to model the truck-shovel system as a multiple-chain closed queuing network. This approach would provide the capability of estimating system performance measures for planning purposes when the truck fleet is not necessarily composed of identical trucks. An example of truck-shovel systems is discussed to show how the incorporation of different types of trucks does affect performance measures.

Jan 1, 1996

By Charles H. Wells

This paper describes a commercial installation of a sophisticated instrumentation and control system designed to maximize the performance of heavy medium cyclones. Samples of plant feed and its products were collected and analyzed for ash content so that measures of efficiency could be determined for plant operation under (1) manual control and (2) automatic (computer) control. The heavy medium cyclone control strategy and its digital computer implementation are discussed in detail. The sample results are analyzed and the economic benefits of automatic control are discussed. Results from the initial data sets quantify the economic benefits of automatic closed-loop control; viz, increased recovery and reduced clean coal variability have been clearly demonstrated.

Jan 1, 1981

By P. Eger, D. Green

"The Soudan Mine was Minnesota’s first iron mine, operating from 1882 to 1962. The mine was donated to the State of Minnesota in 1963 and became a state park in 1965. The mine discharge contains elevated copper and cobalt concentrations and has been treated with an ion-exchange-resin-based system since 2009. The system includes flow equalization tanks, bag and cartridge filters, a carbon tank and two commercial ion exchange tanks. Although effective, the system’s high cost, inefficient removal of suspended material and substantial maintenance have been ongoing and troublesome issues.In November 2012, we initiated a pilot test using a peat-based sorption media. This media is produced from raw reed-sedge peat through a patented, low-temperature carbonization process that produces a hardened granular sorption material. The granules are uniform, have high hydraulic conductivity and maintain the high metal affinity of natural peat.Mine water was pumped through the peat-based sorption media without any pretreatment. Copper input concentrations typically ranged from 30 to 60 µg/L but increased to a high of 364 µg/L in the summer of 2013. Since startup, more than 60 million L (16 million gal or 32,000 bed volumes) have been treated, with average removal rates of 75 percent for particulate copper and 60 percent for dissolved copper. Backwash is required at about 4,000 bed volumes, but with a combination of air sparging and high-flow backwash, the suspended material is removedfrom the media.One tank of the peat-based sorption media was found to remove copper similarly to the first four components of the existing system. By reducing size and complexity, reductions in operation and maintenance costs are possible. A comparison of the estimated costs indicate that replacing the four initial components with the single media tank has the potential to reduce annual operating costs by more than half from around $163,000 to $70,000."

Jan 1, 2015

By Camilo Quintero, Frank Cesario, John Kinnear, Brian Boye

In this paper, an innovative approach was adopted to automatically calculate the effects of tunnel induced settlement on buildings and utilities. The approach resulted in increased output quality, consistency, reduced time, cost savings and a greater ability to respond quickly to design changes. The techniques described have been applied to the Fairbank Silverthorn Storm Trunk Sewer System project, located within the City of Toronto. The automation allowed a very large area of topography, tunnels (6 km), buildings (9000) and utilities (over 1000) to be rapidly evaluated. Visualization of the settlements and impacts also allowed the project design team to optimize the system design to mitigate the settlement impacts.

Jun 13, 2021

By F. Calizaya

This paper explains and discusses a computer program developed to determine the ventilation design parameters for complex auxiliary ventilation systems such as those found in the construction of long excavations with multiple headings. The program is based on the principle of partitioning the system into segments of finite length, and formulating and solving the resulting networks recursively. The application of the program is illustrated by the detailed solution of an auxiliary ventilation system proposed for the Exploratory Studies Facility (ESF) at the Yucca Mountain project, Nevada.

Jan 1, 1994

By Javad Sattarvand, Amin Moniri-Morad

Predicting equipment failure behavior plays a critical role in providing a safe operation. Although various reliability evaluation methods are available for estimating failure behavior profiles, these approaches are based on mathematical formulation, leading to actual operation simplification and improper estimation of failure trends. This study proposes a discrete-event simulation (DES) approach to model fleet failure behavior. This approach can model the maintenance strategies in multi-component systems with minimum simplifications. In this regard, the first step was to collect a historical failure time dataset (e.g., the time between failures). Then, the DES model is established to predict the severity of failure events and design maintenance strategy considering actual operation circumstances. Afterward, the maintainability analysis was performed to estimate equipment downtime and availability. The achieved results showed that the system availability was about 85%. Also, the findings demonstrated that the DES could efficiently predict the equipment failure behavior using various stochastic events.

Jun 25, 2023

By Gerald Zink

The work described in this paper is sponsored by the Bureau of Mines for the purpose of accelerating the drilling of roof bolt holes and reducing the quantity of materials needed to fill each hole. A high-speed small-hole drill has been fabricated and tested in the laboratory. High priority has been given to safety, reliability, and compatibility with underground coal mining practice. The combination of drag bits and erosion jets is designed for high penetration rate, long wear life, and uniform hole size in a variety of sedimentary strata. A reliable high-pressure high-speed swivel feeds water to the bit at about 4 1/min (1 gpm). The duplex hydraulic intensifier which drives the jets has a 40 kw capacity (30hhp) Results of recent full-scale laboratory testing are presented.

Jan 1, 1978

By Sah Rameshwar, T. Umadevi, K. S. SRIDHARA

In the magnetite iron ore pelletization process, oxidation of magnetite followed by sintering of the oxidized magnetite (hematite) is desirable. Optimum preheating time & temperature and roasting time & temperature is required to get the desired properties of the pellets with magnetite, hematite, and hematite–magnetite blend. In order to utilize the magnetite resources in a current induration furnace, which is designed for hematite resources, detailed pelletization studies have been carried out to optimize the firing cycle for magnetite concentrate as well as magnetite with hematite concentrate. Under optimum conditions, such as preheating temperature 1000–1150 °C, preheating time 10 min, roasting temperature 1250 °C and roasting time 7.5 min, the cold compression strength (CCS) of magnetite roasted pellets was 325 kg/p, and this was due to recrystallization of secondary hematite particles, and development of the strong slag bond between primary and secondary hematite particles. The strength of hematite concentrate pellets was 260 kg/p. From laboratory studies, it was found that without disturbing the induration furnace firing cycle, which is designed for hematite ore ~5%, magnetite concentrate can be used along with hematite concentrate in pellet blend and the strength of the pellets was 270 kg/p. As the magnetite concentrate increases in the blend beyond 5%, the preheating zone residence time should be increased or a supply of extra oxygen is required. Laboratory as well as plant investigation has shown that the addition of magnetite to the hematite mix blend improved the strength of the pellets compared to hematite pellet alone.

Oct 26, 2020

By Roe-Hoan Yoon

INTRODUCTION In 1960, coal accounted for 49% of the world energy consumption, an amount that was reduced to 29% in 1973 because of the availability of cheap oil. At that time, it seemed that oil would remain available for a long time in unlimited quantities. However, this situation changed drastically in 1973/74 when a series of closely spaced price increases from $3 per to $12 per bbl by mid-1974 hit both industrialized and developing countries. Another sharp price increase in 1979/80 to the $34 to $38 per bbl level also hit the world economy hard and, at the same time, set in motion powerful technology development forces for increased coal utilization. At this point, the price of coal was approximately $1.50 per MM Btu, while that of oil approached $6.00 per MM Btu. This huge price differential offered an incentive for developing new coal technologies including liquefaction, gasification, fluidized bed combustion, coal-water mixture (CWM), etc. The CWM technology was of particular interest to the utility industry, which consumes more than 80% of the coal mined in the US for power generation. In this technology, a powdered coal is mixed with water to produce a stable slurry that can be stored for an extended period of time without settling and is readily pumpable. Various reagents in the amount of approximately 1% by weight of the coal are added to inhibit sedimentation during storage and to reduce the viscosity for atomization in burners. The coal loading is in the range of 50 to 80% solids, depending on the particle size and its distribution. With very fine particles, it is difficult to increase the coal loading above 50%, and a binomial distribution helps increase the coal loading. The presence of water consumes a relatively small amount of the heating value of the coal during combustion; for a coal-water slurry containing 30% water, less than 5% of the calorific value of coal is usually consumed due to evaporation. The major advantage of burning coal as a slurry is that many of the oil-burning furnaces can be converted to coal-burning with a minimum retrofit cost. Considering the substantial price margin between coal and oil, the pay- back period for retrofit costs can be relatively short. Nevertheless, the retrofit cost can be further reduced if low-ash coals are used as feedstocks for CWM; there will be savings in the capital cost of installing bag filters or electrostatic precipitators that are designed to remove the ash from the combustion gases. Furthermore, the use of low-ash coals can minimize derating of boilers because the velocity of the combustion gases can be maximized without creating erosion

Jan 1, 1991

By J. S. Young

During 1975, the Reclasource Corporation constructed and commissioned a plant for the recovery of mill scale, coke breeze, blast furnace dust, blast furnace sludge and basic oxygen furnace dust at the site of Crucible Alloy Division, Midland, Pennsylvania. The Reclaform Process was employed as the criteria for plant design. This Process takes the solid in-plant fines as listed above, commonly found in integrated steel mills, sizes and forms them through the use of a carbonaceous binder briquetting system and cures the binder through a final heat-treating step. 15,000 tons of Reclaform briquets have been tested in the Crucible blast furnace in several campaigns structured to assess material handling properties, burden feasibility and finally culminating in an iron and carbon assessment campaign. Data are presented from the records of the blast furnace operation and conclusions are drawn that both iron and carbon utilization have been demonstrated.

Jan 1, 1977

By Richard R. Klimpel

INTRODUCTION Froth flotation is the most widely used and economic means of concentrating metal sulfide ores such as those containing copper, lead, zinc, nickel, molybdenum, and pyrite. Also recoverable are other metal species that are often associated with sulfide ores such as cobalt, platinum, gold, silver, etc. Froth flotation is a physico-chemical process for separating finely ground minerals from their associated gangue material. The process involves chemical treatment of a finely divided (ground) ore in a water pulp to create conditions favorable for the attachment of certain of the mineral particles to air bubbles. The air bubbles then carry the selected minerals, called valuable, to the surface of the pulp to form a stabilized froth which is removed and recovered. The unattached gangue material remains submerged in the pulp and is either discarded or reprocessed. To obtain the adherence of the desired mineral particles to the air bubbles, at least two specific steps must occur: a hydrophobic (water hating) surface film must be formed on the particles to be floated along with a hydrophillic (water wetting) film on all other particles; and a controlled bubble surface tension interface must be maintained, allowing for high particlelbubble collision frequency and efficient attachment or sticking of the particle to the bubble once collision has taken place. In most flotation applications, the above two steps are controlled by chemical flotation reagents. The collector is a chemical reagent which produces the hydrophobic film on the valuable mineral particle and is the primary driving force that initiates the flotation process. The frother is a chemical reagent which influences the collision frequency and attachment efficiency of hydrophobic particles and air bubbles. Thousands of research papers and books have been published on the chemical theory behind sulfide mineral collectors, e.g., Fuerstenau (1962), Fuerstenau (1976), Fuerstenau, et. al. (1985), King (1982), Leja (1982) and Moudgil and Somasundaran (1987), This article will only address and summarize some of the more practical aspects of collector usage. The industrial scale practice of froth flotation in sulfide mineral concentration has changed little since the 1950's. For example, of the approximately 80,000 metric tons of sulfide mineral collectors used commercially (1980) in the free world, almost 98% were known and manufactured in some form 25 years ago. A very interesting and informative history of collector development has been given by Crozier (1984). In addition, the industrial scale practice of froth flotation applied to sulfide ores has proceeded since the 1920's with often little direct (predictive) scientific explanation due to the extreme complexity of the flotation process. Empirical testing has been a mainstay of industrial flotation reagent development and use. Even today there is often strong disagreement between researchers as to the mechanisms of chemical flotation practices that have been performed successfully at an industrial scale for many years. As a result of the above environment which makes reagent cost/performance analysis difficult for new reagents, there is a strong tendency for the flotation operation to use, and reagent companies to supply, as cheap as possible raw materials and manufactured products that are quite general in application. In the last 20 years or so, there has been increasing technical effort to tailor make reagents for specific applications, but to date such work has had little commercial impact. It is clearly the hope of this author and others that this situation will change in future years as technology improves and pressure for improved flotation performance intensifies. This article is a condensation of collector usage trends quantified as part of a comprehensive industrially oriented applications program on froth flotation organized by Klimpel and coworkers (1979-1987) and as reported in various countries that participated in the program from 1978-1983. No attempt will be made to provide specific.

Jan 1, 1986

By J. W. Cash

The mineralogy and textures of cyclone dust, sludge, and occasional build-ups in the American Iron and Steel Institute (AISI) direct iron making pilot plant at Universal, Pennsylvania have been studied by reflected light, transmitted light, and cathodoluminescence microscopy, and phase compositions have been determined by SEM-EDS. The cyclone dust consists of particles of carbon, metallic iron, sulfur-bearing iron, and wustite. Measurements of particles in the sludge indicate that 69% are less than 2.5 µm across, 21 % are 2.5-5 µm, and 10% are larger than 5 µm. Mineralogically the sludge particles are mainly carbon and metallic iron, with minor wustite and sulfur-bearing iron. Build-ups that sporadically develop in the furnace consist of olivine, hercynite spinel, metallic iron, wustite, pyrrhotite, pseudobrookite, akermanite-ferroakermanite and gehlenite. The microtextures shown by the build-ups indicate that much of that material has precipitated at the build-up loci. This study has been supported by AISI and the U.S. Department of Energy.

Jan 1, 1995

By G. Ferrara

To obtain a reliable comparison between conical and cylindrical separatory vessels used in dynamic dense medium separation systems, the following studies were made: (1) study of the swirling flow in conical and cylindrical vessels using laser-Doppler velocimetry (LDV); (2) study of the behaviour of suspensions of magnetite and ferrosilicon in water in both separators. It was found that: (a) the tangential velocity profiles differ in conical and cylindrical vessels: in a conical cyclone free vortex conditions affect the largest part of the vessel, while in a cylindrical vessel, the motion approaches that of a forced vortex, i.e. that of a centrifuge; (b) the conical vessel manifests higher centrifugal acceleration and very strong densifying; the density differential, and hence the density gradient inside the vessel is large; (c) the cylindrical vessel manifests lower centrifugal acceleration and low densifying, i.e. low density differentials, and hence, the density gradient inside the vessel is small; (c) due to greater densifying, the density cut-point in cyclones is higher than the operating medium density, while in cylindrical vessels the density cut-point is closer to the medium density. The results provide an interesting description of the differing behaviour of conical and cylindrical vessels and help explain the differences in performance between the two types of separators.

Jan 1, 1998

By Thomas A. Boyce

Introduction Although innovative coal extraction technology can be approached from many angles, this paper focuses on three: innovation in response to rising costs, to changing mining conditions, and to regulatory issues. Before exploring these three subjects, however, a basic question needs to be raised. Why Innovation? Coal is widely heralded, and quite correctly so, as the United States' "ace in the hole." It has been said that the U.S. is to coal what the Arabs are to oil. The implication is that we have nearly inexhaustible reserves - that coal is cheap, plentiful, and easy to extract. Indeed, because our current productive capacity is estimated to be 15-20% greater than demand, we have been given a false sense of security about the ease of future coal extraction. Therefore, innovative measures are being concentrated on developing technologies for the demand side of coal, including power generation, synthetic fuels, and industrial applications. What is often forgotten is that the unit cost of producing energy from these new technologies depends critically on the cost of the coal feedstock -in some cases the coal consumed accounts for more than one-third the total cost. Thus, while the developers of the end-use technologies struggle to improve the overall thermal efficiency of their process by one or two per¬centage points to make the energy produced competitive in the marketplace, they often are unaware of the risk of a 3 to 6% increase in coal costs wiping out the expensive, hard-earned results of their research. Energy planners are just beginning to realize that coal is not a uniform commodity available at low cost in infinite quantities. Coal is a heterogeneous material whose cost and quality vary widely with local conditions. To produce the massive amounts of projected coal-based energy at reasonable costs, we urgently need devel¬opments in extraction technology, as well as in end-use technology. Thus, coal extraction, coal conversion and utilization, and end -use energy consumption must be viewed as highly interdependent parts of an energy supply network (Fig. 1). And current emphasis on conversion and utilization must be balanced by more emphasis on upstream technologies, including coal extraction. Even more important, the impacts of innovation (or the lack thereof) in any one technology area in the energy supply network need to be discussed and understood by those working in each of the other areas. Why innovation in coal ex¬traction technology? Figuratively, we are all in the "coal boat" together - geologists, miners, transporters, processors, power producers, distributors, and consumers. Innovation is required from each of these sectors to overcome the obstacles that prevent greater use of our most abundant national energy resource. All other links in the coal energy supply network depend on large volumes of coal produced at reasonable costs. Declines in productivity, therefore, must be reversed; the more difficult mining conditions that will be encountered call for new methods and equipment, and regulatory issues must be resolved if the coal ex¬traction link is to be a strength rather than a weakness in the planned U.S. transition to an economy based more on coal and less on imported petroleum. Innovation Tailored to Regional Conditions Once the importance and urgency of innovative coal extraction technology has been grasped, the next step - implementing a research program - becomes quite

Jan 1, 1980

By Rongdong Deng

A tower-like magnetic system comprising eight permanent magnets was installed at the center of a flotation column to separate chalcopyrite and pyrrhotite minerals. A cyclonic flotation was installed within the underpart of the column to separate the pyrrhotite from the gangues. A three-product magnetic flotation column was fabricated to create a magnetic field and a cyclonic zone. The products were Cu concentrates, pyrrhotite concentrates and tailings. The theoretical magnetic field strengths and the magnetic forces were calculated. The results of the flotation experiments showed that the Cu grade increased from 14.20% without the magnetic field to 26.40% in the presence of the magnetic field and that the S grade in the pyrrhotite concentrates increased in the presence of cyclonic flotation. The separation efficiency of this magnetic flotation column was evident. Therefore, this three-product magnetic flotation column may have a potential application, due to its high separation efficiency.

By Pierre Filiatreault, Brian Straight, Stephanie Thibeault, Devin Castendyk, Londie Cameron

"Working on or near water at active, closed or abandoned mine sites is inherently dangerous. Between 1996 and 1999, the U.S. Mine Safety and Health Administration (MSHA) reported 17 fatalities involving drowning at U.S. metal, non metal and coal mines (MSHA, 2000). Openpit mines which fill with water following mine closure, called pit lakes, present numerous risks to environmental monitoring teams including: a) drowning, b) hypothermia, c) falls to the ground from the top of high walls, d) collapse of unstable access roads, e) rock falls and avalanches from pit walls, f) avalanchegenerated tsunamis traveling across the lake surface and g) rapid degassing events.Some pit lakes are simply not safely or easily accessible for ongoing monitoring. However, the routine collection of water samples from the entire water column on a regular basis is needed to monitor the evolution of water quality over time, verify the accuracy of numerical predictions and, ultimately, manage lake water chemistry and ecological risks. For pit lakes with surface water discharge, regular monitoring is used to appropriately design and adjust water treatment plants in order to produce acceptable site discharge water quality.As a product of these risks and the need for water samples, mining companies spend considerable expense on pit lake safety as part of monitoring programs. This includes training personnel for on water duties and hazards, purchasing or hiring specialized equipment and personnel (such as boats, boat operators, personal floatation devices and cold-water clothing called mustang suits), stabilizing pit walls and maintaining safe access roads to the lake surface and employing spotters who can directly communicate with emergency medical services to watch sampling activities because cell phones and radio signals can be blocked by pit walls. Some sites utilize redundancy to prepare for unexpected incidents and accidents. For example, one Canadian mining company requires two boats on the water during pit lake sampling events, with a third boat on the shoreline, gassed and ready to go. In addition, water samplers are required to hold Marine Emergency Duties training to ensure the entire boat crew is sufficient and competent for the safe operation of the vessel in the event of an accident."

Jan 7, 2017

By Yashar Pourrahimian, Magreth S. Dotto

Fragmentation by blasting is a critical process in hard rock mining. The blasting process and outcomes are highly influenced by rock mass properties and their response to higher stresses and loading rates. Each rock mass is unique, but some features affect the blast energy similarly, leading to similar outcomes. Having analyzed these features and their influence on blast results, they can be incorporated into the blast design to achieve better outcomes. This paper presents a numerical model validated by a case study from the actual mine blasts that studied the effect of rock mass properties on explosive energy production, attenuations, and overall blast outcomes. The results show that when the model parameters are calibrated based on real data, they can be used to simulate the fragmentation process and therefore be used to aid blast design.

Jun 25, 2023

By K. Vanbroekhoven

An industrial site near the centre of a historical town in Flanders is characterized by chromium(VI) contamination of the groundwater. Since the potential for natural attenuation was not sufficient to control the groundwater plume as observed from different analyses like pH, Eh, soil oxidation and reduction capacity, the feasibility of site remediation based on in-situ bioprecipitation of chromium was examined in lab microcosm studies. By creating reducing conditions by addition of a carbon source in the groundwater, chromium(VI) can be biologically reduced to chromium(III), which can form an insoluble precipitate of chromium(III) hydroxide. Microcosms contained contaminated groundwater and aquifer samples that were collected and manipulated under anaerobic conditions. Three different carbon sources were screened for their effectiveness: molasses from sugar beet production, molasses form starch production (protamylasses) based on potato juice and lactate. The different concentrations of sugar molasses were used to determine the optimal conditions. A range of parameters was monitored at regular time intervals for a period of six months such as chromium(VI) and chromium(III), DOC, methane, pH, Eh. A rapid conversion of chromium(VI) to chromium(III) was observed for all conditions tested. However, extensive removal of chromium from the groundwater by precipitation was only achieved for a limited number of conditions. In general, lactate was found to be the most effective carbon source, slightly better than the lowest concentration of sugar molasses that was tested, which itself was more effective than molasses based on potato. Higher concentrations of molasses, although causing a steeper decline in redox potential, resulted in less effective Cr removal. Typically, the fermentation of molasses results in acidification and this drop in pH may hinder the formation of insoluble chromium(III)hydroxides. It may also be possible that certain components of the molasses form soluble complexes with chromium(III). For lactate, no significant drop in pH was observed. Following the laboratory microcosm tests, the stability of the chromium precipitates was examined by performing a sequential extraction on the microcosm materials. These were performed under redox conditions which were similar to the ones observed in the field. Since the outcome of these tests was positive, a pilot scale test was implemented in the field in April 2005. Two different substrates, the cheap waste product sugar molasses and lactate are being injected creating two different impact zones and typical parameters are monitored. Frequent re-injections were important to maintain reduced conditions and are carried out three-weekly up to now. To study the stability of precipitates formed, mesocosm socks containing aquifer material were installed in the monitoring wells and harvested at regular intervals. Results of this pilot test will be presented and compared to the laboratory results. Based on the success of this field test, a full scale process will be designed and implemented as remediation strategy.

Jan 1, 2006

By K. F. Unrug

Extrapolation of the rock properties obtained from the cores exploration holes to the surrounding areas often causes problems because of frequent sudden changes in the geologic composition of strata. To address this problem, the author has been developing a method of rapid strength testing "in situ," with application of a borehole penetrometer. This method, as opposed to conventional laboratory testing, does not require rock samples to be retrieved and handled/machined before testing. The results are generated by strength determination on the wall of a drill hole at a site. The newest development is a borehole penetrometer that requires only a 1.38.mm (1.5 in) diameter hole. The small diameter of the penetrometer body allows for drilling test holes with production mine equipment such as roof bolters. It opens the possibility of broad application in coal mines, as well as in hard rock mines and tunneling. The principles of the apparatus are described and are illustrated with examples of its applications.

Jan 1, 1999

The Functional Performance Equation for ball milling circuits provides plant staff with a new means to improve circuit performance. However, successful execution of a plant project, with verifiable circuit processing performance improvements, requires a significant number of accompanying steps beyond the equation alone. In order to identify and articulate all these steps, a study with plant staff from two milling operations and a grinding media supplier was undertaken. ?Task analysis? of improving plant grinding performance was carried out. This analysis called for the development of a number of system components, and ultimately yielded a ?Plant Grinding Circuit Processing Performance Management/Improvement System.?

Feb 23, 2014