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By B. Tönjes

In the course of the last decade, the concept of sustainability has turned from a catchword into a vision - a vision to which politics and industry feel increasingly committed. In terms of the energy industry, the key criteria for sustainable development are supply security, economic efficiency and social responsibility. Coal is able to meet all these criteria if it is produced in conformity with high safety standards through the use of modern mining technology and converted into electricity with the aid of environmentally friendly methods. Among the fossil energy resources, coal will, according to the vast majority of global energy scenarios, continue to be the most important input energy in power generation for the foreseeable future. Coal is therefore today, and will in future continue to be, an important element in ensuring sustainable energy and raw material supply, worldwide, in Europe and also in Germany.

Jan 1, 2005

By R. J. Nankee

Recent on-going efforts to develop commercial coal cleaning beneficiation processes using chlorinated solvents-as the separating media will be described. True heavy media separations were performed on raw coal feedstocks, including Pennsylvania anthracite; Western, Eastern, and Midwestern bituminous; and lignite coals. Separation techniques included bath-type devices, cyclones, and liquid/liquid partitioning. Details on separation devices, removal of solvent, and recovery and recycling of solvent will be discussed. Projected costs of full-scale plants will be given for various coal sizes. A number of the coals evaluated are good candidates for beneficiation using chlorinated solvents. Coal beneficiation is desirable to provide needed coal quality. These needs include low ash fuels for coal water slurries and low sulfur fuels to meet emission regulations. In October of 1985, a paper, "Chlorinated Solvents for Coal Beneficiating"' was presented at the fall meeting of SME-AIME at Albuquerque, New Mexico. It reported the results obtained from various coals as feedstocks and of the separations using chlorinated solvents. These beneficiation results depended on true heavy media gravity and liquid/liquid partitioning separations. This paper will include detailed descriptions of the liquid/liquid partitioning process used in "Dow's Advanced Coal Cleaning Technology?2 and of the "Dow Solvent Recovery Technology.?3

Jan 1, 1987

By M. M. Fine

One of the most persistent topics at technical gatherings and in the recent scientific press has been the reduction of iron ore. To cite some of them, in May 1960, a symposium on the subject was sponsored by the Electrochemical Society. The proceedings, comprising two dozen papers, were later published.3/ More recently, November 1966, a similar gathering took place at Michigan Technological University, Houghton, Mich. The latest meeting was the International Congress on Production and Utilization of Reduced Materials, Evian, France, May 1967. If the volume of literature, symposia and conferences is a measure of industry concern, then current interest must be at a high level. To the casual observer of the metallurgical scene, the abiding and recurring attention to iron ore reduction outside the blast furnace must be somewhat puzzling in that so much research endeavor has resulted in so little commercial activity.

Jan 1, 1968

By W. C. Streib

A wide variety of materials have satisfactory to superior insulating properties and can be used to control the flow of heat, provide energy savings, improve personal comfort and contribute to personal safety. Such materials range from completely organic products--both of natural origin and synthetics--to completely inorganic. In many cases, thermal protective systems are actually combinations of both. Obviously, those insulating materials which are principally inorganic have the inherent advantages of low to minimal combustibility as well as utility at vastly elevated temperatures. Both of these properties are highly desirable in providing not only thermal energy conservation, but also personal safety in residential and commercial applications. As the thermal insulation needs of man and industry have developed, there has been an ever-increasing demand on the minerals industry to provide the resources required to fill these needs. On a global scale, industrial minerals have become the fundamental base upon which today's thermal insulation industry has been built. The use of minerals to control heat flow range from the most unsophisticated applications to those requiring the ultimate in scientific technology. In many cases the minerals are themselves converted in- to the major insulating media; for example, fiber glass, rock wool or refractory fiber. In other cases, minerals are used as the chemical reactants to form the binder matrix which in turn provides the product strength required for adequate handling and installation; for example, calcium silicate bonded products wherein the binder is the reaction product of lime and silica. In still other cases, low density mineral products are added to a high density binder System to provide lower weight and better insulating properties; for example, the use of expanded perlite in concrete.

Jan 1, 1976

By Jorgen Elbrond

In a stream of ore in an underground mine or in a beneficiation plant bins are installed between machines or machine system. When the upstream machine is stopped the downstream machine can continue operation for a while and vice versa. The paper describes a procedure for calculating the total capacity of a system consisting of two machines with an intermediary bin as a function of the bin's live volume and of the installed machine capacities and their production variations, which are defined. Extensions to several machines in parallel and in series are shown as well as practical examples.

Jan 1, 1982

By Hugh E. Cronin, John Ramage

The recommendations resulting from a Dispute Review Board (DRB) hearing of a contract dispute are being challenged more and more frequently. This paper explores possible causes based on the authors’ experiences. Challenges facing the DRB process include: The DRB process is starting to lose some of the informality and flexibility. Both owners and contractors appear to be putting too much weight on a board recommendation on a dispute. DRB’s do not make “decisions,” they provide recommendations for dispute resolution to both parties. The DRB process is not just for contractors to present an unresolved issue to a board hearing. Owners can also initiate a request for a hearing on a disputed issue. For the DRB process to remain a viable element of the successful construction project, confidence must continue to be maintained in a process that is intended to work on behalf of both parties to the construction contract.

Jan 1, 2003

By V. Avdiyskiy

The most pressing topic raised nowadays by the world community faces environment and social consequences of the business intensification process, primarily that of mining and mineral industry, which is through the number of its activities mostly associated with pernicious impacts. World top managers are confronted with the dilemma of reconciling traditional financial framework aiming at successful business development measured by revenues, shareholder value, profit margin and incorporating Sustainable Development (SD) at all levels of decision making process, avoiding depriving future generations of the means to meet their own needs. The rapid consolidation and globalization of the industry stipulates that companies are an integral part of the world economic environment. Therefore a company?s financial performance is under the pressure of operational and environmental performance. Among them special attention is paid to the social and economic background, the relationship with regulatory institutions, and the developments for environmental protection.

Jan 1, 2003

By J. R. England, W. J. Taylor

The Sudbury Basin is the scene of the mining operations of the Ontario Division of the International Nickel Company of Canada, Limited. Around the rim of the geological formation and within thirty miles of the City of Sudbury are located twelve operating mines and one open pit operated by the Company. The City, with a metropolitan population of some 100,000 lies 240 miles Northwest of Toronto. In addition, there is one mine in Northwestern Ontario, at Shebandowan, 700 miles Northwest of Sudbury. In 1973 these mines produced 16.5 million short tons of ore of which 14.9 million tons were from underground and the balance from open pit operations. Mining methods include blasthole, sublevel caving, induced caving, shrinkage, cut-and-fill and undercut-and-fill. Raise boring commenced at Inco in 1964 and is now applied at all mines in the Sudbury District (Figure 1). [ ]

Jan 1, 1974

By P. C. Thakur

The history of coal mining in the United States of America and the rest of the world is replete with mine explosions and consequent loss of lives. Serious efforts in the USA to recover methane prior to mining and post mining started about forty years ago. CONSOL Energy Inc. and government agencies, e.g., the erstwhile US Bureau of Mines developed several techniques of methane drainage, such as in-mine horizontal drilling, vertical gob wells, hydrofracing of vertical wells and horizontal drilling from surface. With the current technology, thirty to sixty percent of total methane emissions from a mine can be captured making the mines much safer and more productive. Drained methane is often marketed to defray the cost of methane drainage. This paper is an anthology of these developments and describes how coalbed methane, which used to be a bane, has become a boon for the coalmining industry.

Jan 1, 2003

By Keith G. Wallace, Malcolm J. McPherson

In order to model accurately a mine ventilation system in an existing mine, it is necessary to determine the resistance to airflow in all main airways. This is accomplished by measuring the airflow and pressure differential in each airway. Gauge and tube methods have been used to determine pressure drops in ramps and level airways. However, it has rarely been used in evaluating the frictional pressure drop in shafts. Because shafts commonly have the highest pressure loss in mines, it is critical that the resistance of these airways be determined accurately. This paper describes the theory and practice of using the gauge and tube method for determining the pressure drop in shafts. The pros and cons of using this method are discussed as well as a comparison between the gauge and tube and barometer measurement techniques. Case studies showing the accuracy of shaft gauge and tube measurements are also presented.

Jan 1, 1991

By Markku Virtanen, Pertti Koivistoinen

From the perspective of a large mining company the comminution circuit design is worth keeping within the boundaries of the organisation. The correct circuit design begins from the understanding of the role of grinding. Grinding is a link only in the long "comminution chain," starting from solid rock and ending at the concentrating stage. The final target in comminution is to take a part in the maximization of Net Smelter Return, which goal provides the simultaneous considering of capital costs, operating costs and the economic effect of process results. As a general rule there will be a single crushing stage only, ahead of the grinding process. Grinding does not use any metallic grinding media at all, and there will be fine crushing for critical material in the grinding circuit. Grinding has a minimum two stages, besides, at many concentrators middling products and quite often also tailings are reground.

Jan 1, 1997

By D. R. East

Recent experiences within certain sectors of the international mining industry suggest an underestimation of the environmental risks associated with the design of mine waste-management facilities. These experiences show that the technical and managerial challenges of responsible mine waste management is not always fully appreciated. Unfortunately, the image of the mining industry's environmental performance is negatively impacted by a relatively few number of failures. This negative view overrides the many positive contributions made by the majority of mining companies. The fact that these failures continue to occur in developed and developing countries is indeed re¬markable and indicates a degree of risk-taking approaching unacceptable levels. The design requirements for tailings storage facilities are, in many cases, more demanding than those of conventional water dams because seepage of fluids that contain dissolved metals may pose a greater threat than the mere loss of water.

Jan 1, 2000

By W. F. Hahnert, P. A. S. Ralston

In off-line training of a rule-based controller, the significant measure of successful training is the quality of control provided by the generated rule set. In an adaptive or on-line control environment, performance is also measured by the ability to accurately maintain a satisfactory rule set, but within constraints on speed and/or resource availability. Very small population genetic algorithms, or microGAs, have been proposed as a means of capitalizing on the hill climbing characteristics of faster local optimization techniques while requiring less memory and retaining much of the robustness of traditional, larger population genetic search. A traditional genetic algorithm and a similar microGA are developed and applied to two control problems. The performance of these algorithms is analyzed with respect to (1) the quality of the rules learned, (2) the rate at which learning occurs, and (3) the memory resources required during learning.

Jan 1, 1993

By Greg Blerie

The requirements placed on belt conveyors grow increasingly complicated No longer is it sufficient for the conveyors to merely move material from "Point A" to "Point B. " Now these systems must be able to produce a specified flow, guaranteeing a plant can operate as scheduled without peaks and valleys in material flow and production rate. In addition, the conveying system must provide effective control, to minimize the problems and costs associated with the escape of fugitive material these problems include unscheduled shutdowns, premature equipment failures, regulatory headaches, poor neighbor relations, and health and safety issues. The key to accomplishing these goals is the loading and discharge of the conveyor belts. Fortunately, new designs for the chutes that accomplish conveyor loading and discharge can move material efficiently, without blockages and while minimizing the amount of dust generated This innovation is the development of engineered flow chutes

Jan 1, 2004

By Jin Kim, Jerry C. Tien

Water is still the most economical and popular means of controlling dust underground. It is a process that captures dust by bringing water droplets into intimate contact with coal particles. Wetting agents, also known as surfactants, can be added to greatly facilitate such a process since they tend to reduce the interfacial tension between the coal particles (usually hydrophobic) and the liquid. The surfactants used in the study were first chosen on the basis of their HLB (Hydrophile-Lipophile Balance) value, and later tested in order to select the right type and amount of surfactants to give the best performance. Both static and dynamic tests were later conducted using different types of surfactants to examine their respective wetting effectiveness on coal particles. Experimental results show close correlation with the theoretically calculated collection efficiency that is based on a horizontal tunnel and a solid-cone water spray.

Jan 1, 1993

By Robert M. St. Louis, Janet M. Edgecombe

The Mercur Mine's autoclave is an alkaline pressure oxidation system, operating at 220°(428°F) and 3061 kPa (444 psig) (total). Up to 725 metric tons (800 st) of ore, grading 2.02 g per mt (0.059 oz/st) Au and containing 1 to 2% sulfide sulfur, are treated daily in this circuit. A mineralogical and chemical investigation was initiated to locate the cause of lower than anticipated gold recoveries. Greater than 70 wt. % of reduced sulfur is oxidized; therefore, the autoclave is operating at specification. The low recoveries were attributed to increased concentrations of organic carbon in refractory ore. Activated carbon concentration in the attached CIL circuit was increased from 15 to 40 g per 1, leach temperature held below 21°C (70°F), and carbon flow changed to counterflow. These measures resulted in gold recovery improving from 75 to 82%.

Jan 1, 1990

By O. A. Bascur

The problem of setting the proper control objectives and/or having several objectives to be met in the implementation of grinding control strategies can be resolved. The design and implementation of a distributed control system for safe operation of a grinding circuit while maximizing profit is presented. An optimal recovery through- put target for a desired grind is accomplished by advanced control strategies at the DCS level. A mill load constraint control technique provides stable operation with a substantial increase in throughput, while the desired grind index is maintained by an inferential grind control technique without using a particle size analyzer. The integration of crushing/grinding and flotation in the overall design was the key to the success of the project. This synergistic effect was obtained by implementing a computer plant management system in the concentrator. The overall/philosophy was to keep the implementation simple while using new technology creatively.

Jan 1, 1991

By Brian K. Failon

Scale formation is a problem that affects many mineral processing systems because the processes require the use of large volumes of water. Scale composition may vary from circuit to circuit, but the scale deposition mechanisms and needs for prevention are often somewhat similar. Likewise, there is a degree of commonality in the prediction, detection, and elimination of scaling conditions in various water systems. This paper briefly reviews some of the conditions which lead to scale formation, as well as some of the common problems associated with unchecked scale growth. The primary focus of the paper is on the variety of chemical scale inhibitors available for use in mineral processing circuits, and the actions of each type. The means of predicting and detecting scaling tendencies are also addressed, and include both direct and indirect methods, i-e., stability index determination and chemical analysis of deposits.

Jan 1, 1986

By T. Rockley, B. Goertz, S. McDaniel, J. Brune, K. Bakhsh

"Researchers at the Colorado School of Mines, under a project funded by the Alpha Foundation, have developed a working prototype of a dust sample collection device designed to determine if sufficient rock dust has been placed in an underground coal mine to prevent coal dust explosions. When used in conjunction with the Coal Dust Explosibility Meter (CDEM), the device will provide near instantaneous results on the quality of rock dusting at the tested location. The sampling device applies a pulse of air to a testing surface and collect a representative sample of mine dust based on the pneumatic entrainment process during a mine explosion. The use of both physical testing and Computational Fluid Dynamics (CFD) modeling has allowed researchers to refine the design to accurately represent the particle entrainment and optimize the sample size collected for the CDEM. The prototype is being tested in a mine environment to produce information of usability and practical aspects of mine dust sampling. This paper is a progress report summarizing the current status of sampler development. Researchers expect to have a fully developed and tested sampler in early 2016. INTRODUCTION Underground coal mines face the danger of methane and coal dust explosions. The disaster at Upper Big Branch mine (2010) has demonstrated the impact of a violent coal dust explosion that fatally injured 29 miners. Reviewing the history of coal dust explosions, researchers found that that mine operators and mine inspectors do not have a reliable method of collecting dust samples to assure that sufficient amounts of rock dust have been places to inertize the coal dust. This is a problem specifically with small mines that do not have dedicated safety departments to track rock dusting work. The aim of this research is to develop a simple, portable device that can help underground mine examiners collect dust samples from workings and test the explosibility of the sample near instantaneously. Researchers determined that the current brush-and-pan sampling method required by MSHA (MSHA 2013) is flawed in several aspects: Mechanical sampling with a brush exerts forces on the mine dust that may differ significantly from those present during an explosion. Also, U.S Bureau of Mines research (Nagy 1965) has determined that only the top 0.125 inches of the mine dust layer will be entrained in a coal dust explosion. Using a handheld pan and brush, it is difficult to correctly and repeatably sample a layer of this exact thickness. The following will describe the CFD modeling and experimental testing for the development of the prototype sampler. Researchers analyze the accuracy and performance of the prototype during the course of the build process."

Jan 1, 2015

By J. C. Yingling, J. W. Leonard

Introduction The absence of coal-face particle management heavily penalizes the transportation of coal from initial loading to final consumption. The penalties include dust problems, significantly reduced mine-loading-cycle productivity, mine-belt spillage, excessively high coal-preparation costs, chute blockages and dangerous pulverizer blockages at the final point of utilization. Fine particles commonly cause environmental and economic problems. It is well known that these fines can cause safety and environmental dust problems. But it is not well understood that these fines can also swell broken coal to a point where 5% to 15% more time and capacity must be used to deliver the same tonnage. In this paper, methods and rewards for reducing and/or managing fines at the mine face are discussed. Computer-based loading-cycle model productivity estimates, viewed from a new perspective, are made on the basis of material volume rather than on the long-established, and frequently misleading, basis of tonnage. It is typically the volume of broken material being transported that defines the capacity of a given transportation system, while the corresponding tonnages are merely a reflection of the specific material densities. Published evidence suggests that the swelling of broken coal can be decreased very significantly using small quantities of certain nonfrothing chemicals, which are added to mine-face spray water, and by employing improved mine-face breakage practices. In a future paper, the effects on transportation productivity beyond the coal mine will be discussed. The precursor to the work presented in this paper, involving the bulk density improvement for broken coal and the subsequent production gains for underground coal mines, was earlier presented in Leonard and Newman (1989). In the past, this topic has been studied and practiced only in byproduct coking in the steel industry. However, a potential exists for an increase in coal-industry productivity by improving the bulk density of coal to yield a subsequent reduction in delivered cost. This can occur with breakage, handling and treatment methods resulting in the loading of greater quantities of coal in fixed volumetric capacity haulage units such as mine cars, shuttle cars and scoops. Laboratory-based experiments to achieve an increase in productivity by increasing coal bulk density were discussed in Leonard, Paradkar and Groppo (1992). Chemical techniques using small quantities of commercially available reagents (surfactants) resulted in about a 13% to 15 % increase in bulk density, which was thought to produce a proportional increase in the productivity of a mine, together with a subsequent reduction in cost. The idea is to mix the reagents with the water that is used to spray coal during mining. In this paper, the impact of bulk density improvements on production rates is presented. Increases in production ranging from 60% to 88% of the bulk density increases are projected. This analysis was performed for atypical continuous-miner section. In the following sections, discussion and results of the analysis are presented. Discussion An analysis was performed to ascertain the impact of bulk density improvements on face-production rates for a typical continuous-miner section. Figure 1 illustrates the section layout and cut sequence. This layout and sequence is identical to the case described in King and Suboleski (1991). As can be seen, the section uses five entries and 12.2-m cuts that are taken by a remotely controlled continuous miner. The seam height is 1.5 m and two shuttle cars (5.7 t nominal capacity) are employed for haulage from the miner to the section feeder, which, throughout the cut sequence, is positioned as illustrated in Fig. 1. The simulation model was coded in the SIMAN simulation language. The major impacts of increased bulk density improvements on such a production system are as follows: •Shuttle-car payloads, in terms of the mass of coal transported per haul cycle, are increased proportionally to the increase in bulk density that results from the application of surfactant. •Shuttle-car discharge times should remain largely unchanged, because they are determined by the volume of material that is discharged, rather than the mass, and this volume does not change.

Jan 1, 1996