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By Robert A. Jankowski, Natesa I. Jayaraman, Jay F. Colinet

The U.S. Bureau of Mines evaluated the dust control effectiveness of two-phase flow systems in a full-scale model mine using a mockup of a Joy 14CM continuous mining machine. In a two-phase flow system, air and water flow simultaneously through the nozzle. Air pressure varies from 10 to 60 psi, and water at 30 to 50 psi. Coal dust was introduced at the face, and dust concentrations were monitored at the operator locations and in the return. When compared with a conventional spray system, a symmetrical two-phase flow system reduced dust levels during the box cut by 43 pct at the operator location, and 30 pct in the face return. Dust levels, however, increased at the off-operator position during the slab cut. A directional two-phase flow system reduced dust levels at both operator locations by more than 90 pct in the box cut mode. While the use of two-phase flow systems will reduce respirable dust levels and water usage, it requires an air supply to the miner. Moreover, the ability of the two-phase flow system to redirect the dust cloud makes nozzle orientation a critical factor.

Jan 1, 1991

By J. C. Watts

Ball mill grinding circuit control has received increasing emphasis in the past few years due to such factors as declining ore grades, increasing production costs, and advances in analytical devices and minicomputer technology. Since ball mill circuits have been a traditional bottleneck in mineral processing plant throughput, control systems often improve through- put without requiring additional processing equipment. In addition, much of the variability of the grinding product size and consistency is often removed, allowing better process operation downstream. Among the problems which arise in designing and implementing a process control strategy for ball mill circuits are circuit constraints imposed by processing equipment and local management, proper instrument selection, installation and maintenance, and use of calculated or inferred variables for process measurements. This paper discusses these problems and attempts to identify valid approaches to their solution.

Jan 1, 1979

By P. Bevilacqua, G. Ferrara, U. Preti

In the last decade, Meloy developed the IAC - Interfacial Area Conservation - model of liberation. His work included three conservation laws and a mathematical tool called textural transform. This paper reviews the developments and applications of the IAC model. From simple spherical two-phase locked particles with planar interfaces, the model has been developed for curved interfaces and solids with complex textures. Moreover, complex shaped particles and ores having more than two phases have been considered. The model equations give the degree of liberation of the component phases for different ore textures – platy blocky and acicular - as well as for different sue distributions. Lockedness profiles are offered for defining the middlings composition, so that from the model it is possible to predict washability curves.

Jan 1, 1992

By E. G. Kelly

Many methods of evaluating the efficiency of mineral separations have been described in the literature. In most cases, these present the efficiency as a single number. This paper argues that single-number measures of efficiency are inadequate because they seldom allow reliable comparisons, and are unlikely to correspond to the optimum operating conditions. To realistically make comparisons, it is necessary to distinguish the particle-induced component from the equipment- induced component. In a number of situations where the separating property can be identified (such as in gravity concentration and classification), this can often be done. However, in more complicated systems, such as flotation, this has not been possible. A technique is described whereby particle and equipment contributions to efficiency can be distinguished without the need to define the separation property. Because smelter schedules define a boundary correlation between grade and recovery, they generate some of the better single¬-number measures of efficiency, but even these have limitations.

Jan 1, 1991

By Harry M. Edenborn, Richard W. Hammack

Experiments were done to determine if a mushroom compost-based sulfate reduction system could be used to treat nickel-contaminated mine waters. Sulfate reduction systems were established in columns containing acid-washed mushroom compost. Simulated mine waters containing 2000 mg/L sulfate and 50 to 1000 mg/L nickel were adjusted to pH 4.5 and pumped through the columns at flow rates between 15 and 25 mL/hr. During the first nine days of operation, virtually all influent nickel was removed in the columns by sorption and ion exchange mechanisms. The nickel removal rate then dropped to 18 to 30 mg Ni/day (7.8 to 12.8 nmol/ g-substrate/day), probably due to low sulfate reduction rates. When sodium lactate was added to the inflow, a sustained and seven-fold increase in the nickel removal rate was observed. Bacterial sulfate reduction rates measured in mushroom compost-based wetlands exposed to coal mine drainage are 2 to 20 times faster than the rates observed in this study. Low sulfate reduction rates in the columns may have been due to the inhibition of microbial activity by high nickel concentrations and the removal of labile organic compounds from the mushroom compost substrate during acid-washing. Results of this study indicate that bacterial sulfate reduction can effectively treat nickel concentrations up to 500 mg/L if labile carbon is nonlimiting.

Jan 1, 1992

By E. F. C. Ferrett

The benefits derived from the use of main fan evasees or diffusers are well known. If a well designed evasee is fitted to a fan either more air will flow through it or the same air flow rate will be discharged at a lower fan speed. This latter possibility will reduce the air power requirement of the mine, the fan input power and the overall energy costs. Despite these apparent advantages, many reports have been received from the industry of poor evasee performance. After examination, it appears that these problems are often caused by installation difficulties or inaccurate design procedures. The performance of an evasee is affected by several independent factors. Some of these factors describe the evasee geometry whilst others are concerned with the behaviour of the air as it passes through the evasee. This paper shows that the divergence angle is by no means the only ;important parameter which affects evasee performance and that the size of the inlet boundary layer has a significant influence. The performance of evasees of differing geometric shape are compared and the criterion to be used for optimum performance is discussed. It is shown that the commonly used evasee efficiency is a poor indicator of good performance. Recent work by the author and others is evaluated and a simple design. guide discussed. For more sophisticated work, details of a. computer program are provided. Finally, a brief resume of the performance of truncated diffusers is given. Since compressibility effects can be ignored for most mining applications, incompressible flow has been assumed for most of this paper.

Jan 1, 1980

By R. Schmidt

The computational fluid dynamics (CFD) technique was used to analyze and optimize the design of the dynamic air classifier integral to Raymond® Bowl Mills. Flow patterns and particle behaviors were modeled in the RB Bowl Mill equipped with various classifier designs. These CFD simulations resulted in the development of a hybrid turbine classifier that has now been field-tested, yielding significant improvements to both mill throughput and product size distribution. This paper demonstrates the viability of CFD as a tool for air classifier design and as a technique that can be extrapolated for use with other pulverizer and classifier arrangements.

Jan 1, 2004

By Jeffrey J. Schwoebel, Jianliang Li, Daniel J. Brunner

A United Nations (UN) administered degasification technology transfer project, funded by the Global Environmental Fund (GEF) is underway at the Shihao Mine of the Songzao Coal Mining Ad- ministration in the province of Sichuan, Peoples Republic of China. This mine exploits multiple seams at depths ranging from 300 to 600 m below surface. In-seam boreholes and frequently spaced in-mine vertical boreholes, developed from underlying galleries constructed specifically for this purpose, currently degasify the seams in advance of mining at the Shihao Mine. Because of ventilation system constraints and the in-situ gas con- tent, longwall mining of the coals at this mine could not proceed without some form of pre-mining degasification. This paper presents a simulation based degasification plan of long, in-seam horizontal boreholes for the Shihao Mine. Simulations with a coalbed reservoir program assessed time dependent degasification characteristics of both vertical and in-seam horizontal boreholes. The simulations used input data from reservoir and desorption tests conducted at the mine site. The results produced system design nomograms to assist mine engineers in defining the appropriate borehole spacing necessary to degasify the seam in the time available for pre-mining drainage. The predicted effectiveness of the current vertical degasification scheme was compared with that for a horizontal borehole program and served as the basis for the recommended in-seam borehole configuration for the project at the Shihao Mine. The horizontal borehole degasification program requires substantially less gallery and borehole development than the present vertical degasification scheme.

Jan 1, 1997

By R. V. Ramani, R. Srikanth, R. Zhao

A two-part study was conducted to understand the factors affecting respirable dust generation potential or dustiness of coal seams. In the first part, the data from three prior comprehensive laboratory studies was analyzed to establish quantitative relationships between respirable dust generation potential and coal characteristics. This analysis indicates that respirable dust generation rate is positively correlated with Hardgrove Grindability Index (HGI), fuel ratio (fixed carbodvolatile matter), Vitrinke Reflectance (VR), and Level of Organic Metamorphism (LOM). In the second part, specially-designed single breakage experiments were conducted to determine the primary dust generation potential of 17 coal samples obtained from four continuous miner sections, three longwall sections, and the Penn State Coal Data Bank. The single breakage study indicates that primary dust generation rate is positively correlated with fixed carbon content, fuel ratio (fixed carbon/volatile matter), VR, and LOM. Since VR and LOM are strongly influenced by the process of coalification, differences in respirable dust generation rates in different coal seams may be explained by the thermal metamorphism of sedimentary organic matter during subsurface burial.

Jan 1, 1995

By S. Mathur

The southern Florida phosphate deposits that will be mined in the future contain significant amounts of dolomite. Because high MgO levels are undesirable in phosphoric acid production, several flotation schemes for the removal of the dolomite have been attempted. Alternatively, selective flocculation has been suggested as a potential process. A high MgO rock was simulated with a 30:10:60 mixture of apatite, dolomite and silica, respectively. Single mineral selectivity was observed in the apatite-silica and dolomite- silica systems using Polyacrylic acid (PAA) and Poly(ethylene oxide) (PEO) flocculants, respectively. However, no single mineral selectivity was observed in the apatite-dolomite system using PEO. Heteroflocculation, suspected to be the major reason for the loss of selectivity, was minimized by the addition of a site blocking agent (SBA), consisting of a lower- molecular-weight fraction of PEO. Process parameters such as size reduction schemes, flocculant/SBA dosage and pH were investigated to achieve the desired separation. The selectivity obtained in binary mixed-mineral tests was also achieved in the ternary mixed-mineral system, namely, the apatite-dolomite-silica system. In this report, surface chemical characterization of the samples and their flocculation behavior are discussed.

Jan 1, 1995

By R. A. Burns

Kaolin clay has a broad range of applications with the paper market representing the largest end-use. Calcined kaolin finds application in paper, paint and plastics primarily for its high brightness and light scattering ability. It is well known as an extender for TiO2. Meta-kaolin possesses a unique set of physical and chemical characteristics finding use in both traditional kaolin/calcined kaolin markets as well as other unique applications. This paper discusses the intricacies of manufacture and the key physical and chemical properties of meta-kaolin. Specific applications and the relationship of the physical/chemical properties to end-use performance are discussed.

Jan 1, 2002

By Rob McIvor, Joe Keating, Gary Simmons

As more complex ores are processed, finer grinding becomes more necessary. A cross section of several industries will be presented with discussions not only of find grinding issues but also the classification of fine particles. JOHN MANSANTI: Our next topic will be fine grinding. Again, the intent is to present a topic that is generic enough to apply to multiple industries. Our first speaker is Gary Simmons. Gary is filling in for Phil Walker from Twin Creeks. Phil was not able to join us this week, because of some issues they're having with the autoclave. Gary, being involved in the development phase, is very familiar with the topic. Gary spent about three years with American Cyanamid and another four years with Noranda. He also spent some time with Meridian Gold, then became the director of metallurgy with Santa Fe Pacific Gold. He spent seven years there and is presently the director of process technology with Newmont Gold.

Jan 1, 1998

By M. J. Richards, T. X. Ren

Determination of the state of an underground fire plays an important role in fire fighting, rescue and reopening operations. This is normally achieved by the analysis and interpretation of fire gases taken from the fire zone. However, drawing conclusions from gas analysis is not an easy task and needs specialist skills, expertise and experience that are usually beyond the knowledge of the officials in a mine. The complexities of a mine fire and the uncertainties of available information often make effective fire fighting decisions difficult if not impossible. This paper describes a knowledge based expert system that can aid in the diagnosis of sealed coal mine fires. Using a commercially available shell, the expert system has been designed to accommodate a series of diagnostic rules replicating the reasoning logic that would be used by human experts. The system allows the diagnosis of explosibility of the fire zone and trends of various fire ratios to be easily visualised for decision making. By continuously analysing the incoming information, the system is able to provide a rapid assessment of the situation of a sealed mine fire prevailing under specific mining and geological conditions. In addition, short term trends in fire behaviour can be predicted and possible fire control actions recommended. An example is given and shows how this system can be used as an analytical tool in various ways to assist the combating of coal mine fires. Further development of the system is discussed.

Jan 1, 1993

By Babcock. C. O.

This report presents equations derived from experimental testing to convert borehole pressure cell data from vertical and horizontal cells to the biaxial ground stress changes. While hydraulic pressure cells in boreholes have been in extensive use since 1957, methods of data reduction have been slow to develop. The methods of Sellers (1970) and Bauer et al. (1985), respectively, indicate a linear relationship between cell pressure change and the rock stress change. Lu presented a theory for creep behavior (Babcock et al., 1982). In the present work, in laboratory testing, the logarithm of the cell pressure was related to the stress change in seven elastic materials for a range of Young's moduli of 3.45 to 85.5 GPa (0.5 to 12.4 x 106 psi). The gage response depends upon the setting pressure of the gage, the gage pressure at any time, the rock properties, and the cross-sensitivity of the gage to transverse loading. The setting pressure of the cell should be proportional to the Young's modulus of the rock, the absolute stress can be determined by overcoring in strong rock, and the in situ Poisson's ratio can be estimated in some cases from the cell responses.

Jan 1, 1986

By William C. Larson

The number of uranium in situ leach operations has increased significantly since 1975. As of May, 1980, there were a total of 27 active projects, including 16 commercial scale operations (or under construction) and 11 pilot scale operations. The south Texas uranium district and Wyoming have been the most prominent areas in early field experiments as well as in commercial application of this new recovery technique, although in situ leach tests are now being conducted in Colorado and New Mexico. The growing number of commercial-scale operations is accepted as prima facie evidence that in situ mining now offers a third option along with open pit and underground mining for winning uranium from sandstone host rocks. It is estimated that in 1979 about 9 percent of the nation's total uranium production was from in situ mining. However in situ mining of uranium is not without its environmental controls. The primary emphasis of environmental controls falls into two catagories; namely, control of the leach solutions during mining and demonstration of ground water restoration. Finally this paper briefly reviews the Bureau of Mines research program in uranium in situ mining.

Jan 1, 1980

By Garland R. Dever

Extensive deposits of high-calcium limestone occur in the Upper Mississippian Warsaw and Ste. Genevieve Limestones in the region of the lower Cumberland, Tennessee, and Ohio Rivers in western Kentucky. Analyses of foot-by-foot samples from 20 quarries and cores in 8 counties show variations between the chemical composition of high-calcium deposits in the 2 formations. Knowledge of probable variations in composition should aid in prospecting for high-calcium stone for a specific use and in evaluating potential deposits. High-calcium strata in the Warsaw consist of bryozoan- and crinoid-rich bioclastic limestones, and in the Ste. Genevieve, predominantly oolitic limestones. Values used for comparison were obtained by averaging the foot-by-foot analyses of each high-calcium deposit, 10 in the Warsaw and 15 in the Ste. Genevieve. Average MgCO3 and Fe2O3 contents are generally lower in the Warsaw than in the Ste. Genevieve. Average SO2, S, and P contents are- generally higher in the Warsaw. No characteristic differences are apparent between the average CaCO3 and A1203 contents of the two formations. The higher S and P contents of the Warsaw are believed attributable to the predominance of biogenic material in these limestones. Within the Warsaw Limestone, higher average S and A1203 contents and lower average Fe2O3 contents were found in deposits in the northern half of the region. In the Ste. Genevieve, vertical variations in composition occur within individual high-calcium deposits containing oolitic and nonoolitic limestones. Lower average CaCO3 contents and higher average contents for the other constituents were found in the nonoolitic intervals.

Jan 1, 1972

By J. F. T. Agapito, R. R. Goodrich

Yield pillars have been used for many years to help reduce stresses near mine openings and improve roof and floor stability. A yield pillar is often defined as a pillar that fails but retains residual strength. Stress transfer occurs through the roof and floor after the peak strength of the pillar is reached. High stresses are transferred from around the openings onto abutments that can be barrier pillars or unmined ground. This mechanism, often referred to as pressure arching, is possible as long as the width of yield pillar mining (panel width) is less than the critical width above which stresses cannot be carried by the overburden. Significant stress transfer also can occur due to small amounts of pillar and/or floor yielding before the peak strength is reached. This is accomplished in a quasi-elastic manner with little or no visible roof and pillar fracturing or floor heave. Long-term stability may be achieved when stresses and mechanical properties are favorable to prefailure yielding. This paper gives practical examples where improvements in stability and resource recovery were achieved with this mechanism. Yielding was assessed by comparing measured and calculated vertical pillar stresses. Results indicated that calculated stresses in the pillars were 25% to 40% higher than the measured stresses, demonstrating significant arching load transfer to the abutments. Prefailure yielding is probably often present but unintentional in both development and production areas. Better recognition and use of this mechanism should lead to design improvements, as mines become deeper.

Jan 1, 2003

By Ing. E. h. Martin Herrenknecht

The paper will describe a number of developments and innovations now in use in microtunnelling machines. These include the use of fuzzy logic steering systems, the proven ability to successfully undertake complex curved microtunnel drives, the ability to complete ultra long drives using microtunnelling techniques, and machines with access to the face of the machine from inside the machine. The ability to tunnel in relatively hard rock utilizing a rock head with back loaded cutters changeable from inside the microtunnel machine and the ability to utilize microtunnel machines in multi modes, such as hard rock mode, “open” mode, EPB mode, and slurry mode with the same base machine again with access to the face of the machine will be described. In addition, the latest computer technology gives the operator “full visualization” of machine functions together with the ability to data log machine operating parameters. Reference will be made to a number of projects worldwide recently completed or under way where these innovations have successfully been utilized.

Jan 1, 1999

By James S. Scott

Effluents discharged from gold mills, and more recently from heap leaching operations, pose significant hazards to the environment if not properly managed prior to discharge. This paper describes the nature of wastewaters which must be treated, the treatment processes being applied in Canada and the capabilities of these methods in removing cyanide and metals. As a result of past practice the most common method of reducing cyanide in gold mill effluents remains that of natural degradation in tailings ponds. This method has proven capable of producing high quality effluents where large ponds and sufficiently long water retention times can be provided, but at many mines this has not been the case. Since 1981, as a result of these limitations there has been a strong move in Canada to chemically-based effluent treatment plants, particularly as additional processes became available. Canadian gold mills have become leaders in the use of chemical processes to remove cyanide, in terms of the variety of such processes in operation (five in total), the number of plant installations and the number of processes developed in this country. The hydrogen peroxide and Inco SO2-air processes, in that order, are being applied most widely. Alkaline chlorination, the initial process to be used fairly extensively has been almost totally replaced by the two methods mentioned above. Since a number of effective methods are now available for the treatment of gold mill effluents, the selection of a process for application at a specific mill requires careful consideration of:

Jan 1, 1987

By R. C. Kirkman

Your interesting and well-written paper brings up the issue of the purpose or use of a mineral property appraisal, specifically the value of these evaluations when the quality and quantity of the mineral resource to be exploited have not been thoroughly investigated. I am not a practicing professional in regards to valuation of limestone investment opportunities. I simply wish to make a few generic observations about the appraisal process in order to stimulate meaningful thinking by appraisal professionals whose reports may be reviewed by professional investors and "laypersons" alike. It is my contention that the analysis given in your paper is very thorough, considering the data that was made available to you. But I would not like to be the person responsible for investment decision making without having a feel for the risk involved. Therefore, the reviewer must classify this type of analysis as relatively "subjective" because they have not received an indication of the inherent risk involved in exploiting a mineral resource. This risk can best be quantified by using probabilistic methods in conjunction with the quality and quantity of the mineral to be produced. Most appraisals passively ignore this problem. Specifically, you have accurately identified the various costs and values entering the economic appraisal process. These can usually be quantified with a great deal more certainty than the capability of the resource to provide 25 years of quality material. Also, in Cases A (West Virginia)and B (Alabama), you are fortunate enough to have previous operations data. What if there had never been production from these properties? How does a potential mineral property investor evaluate the resource capability to meet various projected financial outcomes without spending a good deal of up-front capital to drill and delineate enough quality resources for a 20-plus year operation. These questions pose a substantial risk to any potential mineral investor. Only probabilistic methods should be used to quantify this type of problem, short of drilling and metallurgical testing. I might be considered a "layperson," not being familiar

Jan 1, 1991