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By R. K. Singhal

In an underground coal mining environment, a frictional ignition may be defined as the ignition of an explosive air/ methane/coal dust mixture by mining machinery. As the use of power loading equipment has become more widespread, frictional ignition incidents have increased. There have been many fatalities and injuries from this cause including the death of eleven miners in Sydney coalfield of Nova Scotia, Canada in 1979. This paper reports on the findings of a preliminary study carried out under the auspices of the Coal Research Laboratories, Department of Energy, Mines and Resources Canada. The objective of this study has been to identify a Longwall face cutting system that is inherently safer than the conventional shearer loaders used in Nova Scotia.

Jan 1, 1985

By X. Li, J. C. Stankus, J. Ma, H. Chen

Accurate evaluation of stress and geological conditions is critical to ground control design in underground openings. For a slope entry, the problem is more difficult, because a slope will transverse through many types of strata. Over the last few years, Keystone Mining Services LLC, an affiliate company of the Jennmar Corporation, has developed a new methodology designated the “Stress, geologic and support design system (SGS).” The method analyzes the stress, geology and support design for a mine slope. The method has been successfully applied in various new slopes across the United States, and ground control plans developed using SGS methodology has helped coal companies successfully pass review and/or hearings by state and federal regulatory agencies. With a case application in the U.S. Midwest, this paper details and demonstrates the main concepts of the methodology, including (1) analysis of stress and geology and identification of strong, fair and weak zones along the slope; (2) primary and supplemental support design; (3) long-term support design in the form of steel square sets or arches and (4) validation of the support design utilizing advanced finite element computer modeling.

Jan 1, 2011

By K. Whiting

In October 1993, the first two of a series of full scale passive biological treatment cells were constructed to treat mine drainage from the Burleigh Mine (located approximately 48 km west of Denver, Colorado in the Clear Creek/Central City Superfund Site). The two cells are each 19-21 m long, 10.7 m wide and 1.2 m deep. Each cell contains approximately 216 cubic meters of substrate (composted manure) and is designed to treat 60 L/min of mine flow. One cell is designed as an upflow reactor and the other cell is designed as a downflow reactor. The differences in flow hydraulics and treatment efficiencies will be tested in these two cell for approximately nine months before the remaining cells are built to treat all the discharge. The substrate material was selected based on a series of bench scale tests. During the tests, the amount of metals removed was determined. The design flow rate was based on a sulfide generation rate of 400 nanomoles of sulfide generated per cubic centimeter of substrate per day. Metal removal results for the first three months of operation of the two cells will be presented and compared to results of bench and pilot studies at other sites.

Jan 1, 1994

By William J. Douglas

Critical path modeling (CPM) has been used widely as a tool to manage large-scale projects having many activities which are conducted in series or parallel. The construction industry is a regular user of critical path modeling as a planning tool. In this context, the method is used to provide an orderly schedule for all activities to forecast delays, slippages, and problem areas and to identify critical activities where resources should be directed. It also identifies others which have slack time, and provides information on the degrees of freedom and flexibility available in completing the project. The purpose of applying critical path modeling to an underground mining system is not primarily for scheduling, but as an analysis tool. In observing underground mining systems, it Is clear that repeated sequences of activities must take place for mining to proceed efficiently. Some of these activities must be sequential, while others be carried out in parallel. The fundamental difference between critical path modeling applied to mining versus a large-scale construction project are: (1) The activities in a mining system are cyclic in nature. (2) The location of the activity varies, and the entire process is not thought of as co-located, as is the case in a construction project. Another important aspect of the network development for mining systems is the degree of detail that is desired. One can be concerned with very macroscopic networks which represent, for example, an entire mine life cycle. Networks representing this problem would be more closely analogous to those of a large construction project. On the other hand, one might be interested in evaluating alternative ways of developing a property or of mining in a given section. More detailed networks representing the section activities are necessary to evaluate system parameters and their impact on long-term production.

Jan 1, 1978

By D. J. Boron, R. Kollrack

Introduction The US has the largest total (364 Gt, or 401 billion st) and recoverable (182 Gt, or 201 billion st) coal reserves in the world (Steam/Its Generation and Use, 1978). However, progressive coal use in this country has been hampered by environmental constraints, such as restrictions on sulfur dioxide, nitrogen oxides, and particulate emissions. Since the promulgation of the Environmental Protection Agency (EPA) New Source Performance Standards (NSPS), it has become apparent that all US coals will require sulfur removal to comply with the new sulfur dioxide emission levels. If more stringent emission standards are imposed, through pending acid rain legislation or amendments to the Clean Air Act, it is likely that the coal industry, and the industrial and utility sectors will look increasingly toward the development of new and advanced coal cleaning technologies to continue and promote the use of coal. Table 1 summarizes the EPA NSPS for sulfur dioxide emissions. Fortunately, the basis for determining sulfur dioxide removal is the Btu and total sulfur content of the run-of-mine coal. Thus, credit is given for any sulfur removed before combustion, e.g., through physical coal cleaning. Unfortunately, physical coal cleaning alone may be unable to produce a compliance coal with respect to the EPA NSPS. Therefore, all industrial and utility coal-fired boilers will require post combustion gas cleanup, e.g., flue gas desulfurization (FGD), to comply with the new regulations. Table 1 - EPA NSPS for SO2 Emission Category SO2 Content of ROM Coal SO2 Reduction Required 1 0-2 Ib/M Btu 70 2 2-6 Ib/M Btu To 0.6 Ib/M Btu (70% to 90%) 3 6-12 Ib/M Btu 90% 4 12 Ib/M Btu To 1.2 Ib/M Btu Alternatives to post combustion gas cleanup, such as staged combustion, lime and coal injection, fluidized-bed combustion, and chemical coal cleaning, are currently under development. Of these, chemical coal cleaning offers the advantages of providing (1) high quality fuel for combustion (low sulfur and ash, high Btu, and attenuated product variability); (2) a solid fuel product for use in retrofitted gas and oil boilers; and (3) a solid fuel product with multiple end uses, e.g., internal combustion engines, carbon electrodes, coke, or chemical feedstock. Gravimelt process In the Gravimelt process, 1.4 mm x 0 (14 mesh x 0), physically beneficiated coal of about 5% moisture is fed into a 3401 to 3901 C (644 ° to 734 ° F) molten bath of sodium hydroxide and potassium hydroxide. Organic and pyritic sulfur and most of the mineral matter in coal react with and are dissolved in a molten mixture of potassium hydroxide and sodium hydroxide. The reacted coal sulfur is converted to alkali sulfides and polysulfides, whereas the mineral matter is apparently converted to alkali-aluminum silicates and other byproducts that are water and acid soluble. Coal residence time is 60 to 240 minutes. The sodium hydroxide to potassium hydroxide ratio is about 9:1. The total hydroxide-to-coal ratio is no less than 10:1. The specific gravity of the caustic melt is about 1.8 g/cm3 . Thus, coal is buoyant in the bath, and insoluble mineral matter with density greater than 1.8 g/cm3 would sink. Reacted coal is first water-washed with an equal weight volume of water in a countercurrent mode of operation. The coal is filtered and the filtrate sent for regeneration. The coal is then acid-washed in 10% sulfuric acid. The acid-water/coal mixture is filtered to recover the final coal product, and the filtrate treated with lime to precipitate dissolved mineral matter. The precipitate is filtered from the mixture and discarded. The water is recycled to the plant. Filtrate from water-washing is treated to remove sodium sulfide. The sodium sulfide is chemically treated to produce hydrogen sulfide, calcium car¬bonate, sodium hydroxide, and other products. The hydrogen sulfide is treated to produce sulfuric acid for the acid-washing step. The calcium carbonate is treated further or discarded, and the sodium hydroxide is concentrated by evaporation and recycled to the reactor. The Gravimelt process is currently at the bench-scale stage of development. A 0.9-kg (2-lb) continuous reactor is in operation with a continuous water- and acid-washing section adjacent. The regeneration section is not developed to a meaningful extent, although key reactions have been tested in the laboratory. Process conditions, product recovery efficiencies, etc., however, have not been determined adequately and continuous regeneration operation has not been attempted. Work is now in progress to develop each section to a continuous bench-scale operation in processing coal at 9.1 kg/h (20 lb per hr). Microwave process The carbon and hydrogen in coal are relatively transparent to microwave radiation. However, water, caustic, pyrite, and other mineral matter components are strong conductors of microwave radiation energy at the proper frequency. As a result, selective heating of the noncarbonaceous materials occurs that enables the chemical reaction of sulfur and ash with caustic. Although very high temperatures may result from

Jan 1, 1987

By Leo Gentile, David Selhorst

The $528 million Toledo Waterways Initiative (TWI) was implemented by the City of Toledo in 2002 and completed in August 2020. Toledo is one of many US cities required to implement a Long-Term Control Plan (LTCP) but one of few to have completed its plan. TWI consists of three storage and conveyance tunnels, four below grade storage basins ranging from 4 to 36 million gallons (MG), miles of sewer separation and interceptor improvements, green infrastructure and other appurtenant structures to dramatically reduce combined sewer overflows to the Maumee River, Ottawa River and Swan Creek. All three rivers flow into Lake Erie. The City’s 180-year history as a Midwest shipping, manufacturing and transportation hub provided design engineers and contractors no shortage of unknown underground challenges to complete the projects. The City will begin its 5-year Post-Construction Compliance Monitoring in 2021 to satisfy the final LTCP requirement. A program overview and experience from tunnel and underground basin construction in urban areas with buried active and legacy infrastructure will be discussed.

Jun 13, 2021

By D. W. Leyshon

The fluidized solids technique for the calcination of phosphate rock has been well established for over 10 years. This paper is intended to review the recent performance of many of the Dorr-Oliver FluoSolids* calciners. In addition, design features of these three compartment refrac¬tory construction reactors will be described and a comparison made with fuel requirements for single compartment calcination. Also presented will be certain, aspects of the use of the rock including a discussion of non sulfate sulfur in the rock. A system is described for producing a blended mixture of calcined and uncalcined rock.

Jan 1, 1972

By M. J. Zdunczyk

Located approximately 50 miles northeast of Knoxville, Tennessee, Short Mountain Silica mines the Clinch Formation, an orthoquarzite, for silica sand. In 1980, a Knoxville resident and area contractor visualized mining Short Mountain for silica sand. Because APG Industries, the main market for the glass sand product, was only 48 kilometers from the site, many silica sand companies became interested in the property. In 1986, J.D. Nicewonder began to develop the site, and in May of 1988, APG Industries received the first sand shipment.

Jan 1, 1992

By Dr. Jagdish C. Agarwal

Kennecott Copper Corporation has developed a new hydrometallurgical process for extracting nickel, copper, cobalt and molybdenum from maganese nodules. This process (KCC Cuprion Process) utilizes a reduction leach operating at atmospheric pressure in the temperature range of 45 C to 50 C and has been successfully demonstrated in a continuous pilot plant processing 800 lbs of nodule ore per day. The chemistry, basic flow sheet and operating characteristics are presented and discussed.

Jan 1, 1978

By Daniel Roy, Danielle Bouffard, Antoine Berton, Simon Gariépy

Commissioning a mineral processing plant has always been a challenging task. The process includes pre- operational verification, dry and wet commissioning, and a gradual ramp-up to full production, all of which must be executed within the shortest possible timeframe, requiring numerous highly interdependent tasks to be conducted concurrently. This phase is under scrutiny by shareholders, corporate management, and other stakeholders who are keen to see a return on investment as the operation starts yielding results. Despite extensive documentation in the literature highlighting its significance, the impact of the commissioning phase remains underestimated in contemporary mining projects. This paper provides an overview of the commissioning process and its associated challenges before focusing on a critical success factor: building a dedicated commissioning team with the required competencies and personality profiles. The roadmap to achieving an efficient plant start-up is outlined. Drawing on over 15 years of experience with more than 20 concentrator commissioning and start-ups, a general framework is presented to maximize success. This method emphasizes the crucial role of the operation and metallurgy team in supporting these projects. Finally, insights from Soutex’s involvement in multiple start-ups are shared, offering lessons learned that emphasize best practices and challenges encountered in expediting the ramp-up process while maintaining high Health, Safety, and Environment (HSE) standards.

Feb 1, 2025

The vast coal resources of North Slope, Alaska can be expected to attract substantial interest because the nearly flat lying coal beds of the coastal plan are specially amenable to surface mining. Mining on a scale large enough to justify coal development in this area could have severe environmental effects. The mitigation would be uncertain because large scale coal mining and reclamation operations have not been carried out in the arctic The deficiency of the scientific data base is another factor that requires consideration if coal mining has to develop in accordance with the objectives of PL 95-87. The objective of this paper is to establish the interrelationship between the problems due to permafrost and factors in reclamation of post mining land in order to find ways to transform nature in a rational and purposeful manner and to suggest specific reclamation approaches that may be appropriate in this region.

Jan 1, 1986

By David Burgess

The paper describes experiments at the Somerset Mine, Colorado, under a cooperative agreement between U.S. Steel and the U.S. Bureau of Mines. A test was made of the tube bundle method of mine air sampling which was developed for European longwall mines; some 300,000 running feet of tubing provided continuous monitoring at 39 locations. Carbon monoxide concentrations were obtained with standard deviations of less than 1 ppm and oxygen concentrations with standard deviations of less than 0.20 percent. A base level of CO index (ppm CO evolved/pct 02 removed)) was determined to be 0-20 through most of the passageways of the mine. However, in one working section where the coal was initially hot (about 180°F within a pillar) the CO index was demonstrably higher, >20 trending upward to about 60 when smoke appeared and the section was sealed. The data are discussed in terms of laboratory experiments on CO evolution from coals.

Jan 1, 1975

By Liaqat Ali Shah, Muhammad Farooq, Zait Ullah Shah, Francisco Rolando Valenzuela-Díaz

Bentonite collected from Nowshera (Pakistan) was treated with NaCl, and the < 2-μm clay fractions were separated by sedimentation process. The textural changes in NaCl treated purified bentonite were compared with raw and physically purified sample. It was detected that the NaCl-treated purified bentonite and the sample purified by simple sedimentation, respectively, consist of sodium-montmorillonite and calcium-montmorillonite as a major clay mineral. The honeycombed-type morphology was observed for both the purified samples; however, the particles of NaCl treated purified bentonite were relatively in a compact form. The particle sizes of both the purified samples were found considerably smaller. The high volume percent of the fine particles was noticed in the NaCl-treated purified bentonite. This attributed that the sodium exchange has a valuable impact on the bentonite dispersion in aqueous media during particle size measurement. The relatively high mesopore area/volume and micropore area/volume and specific surface area (SSA) were detected in purified samples. The NaCl-treated purified sample showed relatively high mesopores area/volume than the sample obtained by simple sedimentation. These changes seem to be originated from either high montmorillonite contents and/or the smaller particle size, which might be produced after the layer rearrangement during the interlayer cation replacement by Na+ ions. The large SSA and high porosity of purified samples particularly the NaCl-treated bentonite suggest their potential use as adsorbents, catalysts, pharmaceuticals, and cosmetics.

Jan 7, 2021

By Josh Savit

Corporate responsibility already encompasses safety and compliance. No longer will companies be able to use differing standards of care to miners based on the country in which they are working. This is not only an issue of social license, but one of global risk management.

By J. Sidhom, W. Fourie

"As the mining industry continues to face difficult challenges the need to persistently focus on productivity and utilization of labor and equipment costs will intensify. With these challenges in mind, Komatsu is helping to bring mining performance and analytics to the next level.By evaluating underground haulage, a significant component of the room and pillar mining value stream, variables have been identified and sensitivities have been performed to show opportunities to balance and streamline throughput. As a result of applying operational excellence tools to the mining environment, Komatsu is seeking to optimize mining performances by limiting waste, simplifying the process, increasing productivity and machine utilization, as well as removing workers from harm’s way.These days it’s not enough to work harder; mines have to work smarter. Improving efficiency, reducing costs, increasing safety: these are no longer nice to haves, they are must haves.Starting with the best products and the right people is a first step, but then what? How do mines take their operations from average to being a top performer? By using operational excellence principles aimed at eliminating waste, simplifying processes, automating where possible and removing people from harm’s way.The fundamentals of operational excellence (OpEx) are based upon the process of define, measure, analyze, improve and control (DMAIC). DMAIC is an improvement cycle that helps with, for example, haulage optimization by: defining the issues and problems in the process as well as the areas of improvement; measuring and collecting mining operational data by time study and equipment monitoring system; analyzing through sensitivities and production modelling to determine root causes and then improving the performance and controlling the operation.Komatsu uses OpEx or lean principles inside its organization to drive efficiency, but it also helps its customers employ them to achieve new levels of productivity and safety.These same principles can be applied in most situations to streamline processes, improve operations and deliver value."

Jan 12, 2017

By M. A. Giralico

Solvent Extraction (SX) technology has undergone significant refinements including outright process changes to achieve greater copper production rates with lower organic entrainment levels. LIGHTNIN has completed a detailed study aimed at improving on the conventional Holmes & Narver and Davy Power Gas type impeller designs1 by optimizing the mixing through the use of high efficiency pumper turbines instead of making system changes as others are doing. Since each individual installation requires a different design head and flow, LIGHTNIN has developed the R320 "family" of high efficiency, curved blade pumper turbines. These impellers are designed to maximize head and flow while reducing entrainment through lower power consumption, less shear generation and turbulence, elimination of air incorporation, production of the optimum droplet distribution, and lower tip speeds. These improvements also maintain the required mass transfer and copper recovery of the traditional impeller designs. The R320 impeller benefits have been quantified using Laser Doppler Velocimetry (LDV) and proven in multiple domestic and foreign installations at flow rates exceeding 15,000 GPM. Design comparisons of this improved impeller type versus traditional technology impellers in head, flow, power and entrainment are presented for review. In addition, the inherent benefits of axial flow, high efficiency impellers like the A3 1 0 and A6000 in auxiliary mix chambers will be discussed. The high flow, low shear characteristics of these patented impellers provide the necessary dispersion stability for mass transfer while speeding phase disengagement in the settlers due to low power and low shear input.

Jan 1, 1995

By B. P. Spigarelli

To meet the growing need for CO2 capture and storage technology, Michigan Technological University is researching CO2 capture and storage using carbonate solutions. The objective of the present study was to increase the absorption rate of CO2 into the carbonate solution without reducing the absorption capacity of the solution. This approach used a polypropylene glycol methyl ether (PPGME) as a surfactant to chemically alter the gas bubble size. Experiments were conducted to study the absorption rate of CO2 at varying surfactant concentrations of 0, 0.12, 0.24, 0.36 and 0.48 g/L. Results showed that as the concentration of surfactant increased in solution, the absorption rate also increased. The CO2 absorption rate increased from 3.45 mmol/min CO2 at 0 g/L PPGME to 3.92 mmol/min CO2 at 0.48 g/L PPGME. This amounted to a 14% increase in the CO2 absorption rate with no decrease in absorption capacity of the solution.

By R. J. Roman

The results of column leaching tests on 3 different mixed oxide/sulfide ores from a Chilean deposit are presented. The 3 samples contained different ratios of oxide copper minerals to chalcocite and chalcopyrite. The results of the column leach tests are interpreted in light of the shrinking core model for coarse particle leaching. The copper recovery from the oxide minerals and the sulfide minerals each conforms to the shrinking core model with the total recovery equal to the weighted average of the individual minerals. The use of column test results to predict field heap leaching results using the multi-mineral shrinking core model is discussed.

Jan 1, 1993

By Julia Herhold

The demand for sustainable and profitable/efficient projects within the tunneling and other underground engineering sectors grows rapidly. Construction tasks play a key role within the project conduction, whether as primary (tunneling), secondary (e.g., mine securing) or tertiary processes (e.g., workshops). The construction tasks of primary processes create the main structures, such as tunnels, which resemble the main project goal. For the secondary and tertiary processes, the purpose of the task shifts. The main goal is to provide structures, such as the securing of the cavity and workshops, that enable the project and enhance the efficiency of the primary conduction underground. To plan and optimize the conduction of construction tasks underground, whether they are identified as primary, secondary or tertiary tasks, the work preparation can be used. This method, known from the above ground construction, can be adapted and used underground. The approach of a digital work preparation tool combines, connects and adapts the main tasks “choice of procedure,” “logistics” and “site planning.” In addition, the digital tool is connected with digital models (construction, site, surroundings). With the adaption and forward projection of the work preparation, underground constructions (e.g., tunneling) can provide a more sustainable and efficient outcome.

Jun 13, 2023

By A. G. Sciulli, G. P. Ballock, K. K. Wu

This paper discusses common environmental problems associated with coal refuse disposal. It suggests design concepts to minimize potential hazards. Discussion focuses on site selection, embankment design and construction, site preparation, facility operation, abandonment, and reclamation. It emphasizes measures that should be adopted in the design phases and during construction of the facility. Recommendations are also made concerning special problems, including seepage, ground water contamination, and mine sealing.

Jan 1, 1987