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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 T. Brozell

"Communities near sand mines and processing facilities in Wisconsin have raised concerns regarding possible exposure to ambient respirable (PM4) crystalline silica. Fenceline PM4 (particulate matter captured with a 50 percent cut size of 4 micrometers aerodynamic diameter) crystalline silica concentration data were compiled at Fairmount Santrol Inc., Mathy Construction Inc. and U.S. Silica facilities. The long-term average PM4 crystalline silica concentrations ranged from 0.05 to 0.45 micrograms/m3 when sample values below the limit of quantification were treated as zeros. All of the long-term average concentrations were less than 20 percent of the Minnesota Department of Health’s and California Office of Environmental Health Hazard Assessment’s PM4 crystalline silica chronic reference exposure level of 3.0 micrograms/m3. The measured concentrations were consistently within the local background concentration range.Air Control Techniques P.C. compiled the sampling data using Thermo Fisher Scientific Inc. Partisol 2000i PM2.5 samplers meeting the requirements of 40 CFR Part 50, Appendix L. These samplers were adapted to capture particulate matter with a 50 percent cut size of 4 micrometers. The use of polyvinyl chloride filters allowed for crystalline silica X-ray diffraction analysis by NIOSH Method 7500. The combined use of adjusted PM2.5 filter-based samplers with Method 7500 crystalline silica analyses provided for a highly sensitive limit of quantification of 0.31 micrograms/m3 of PM4 crystalline silica.BackgroundIn 2005, the California Office of Environmental Health Hazard Assessment (OEHHA, 2005) adopted a 70-year chronic reference exposure level (REL) for PM4 (particulate matter having aerodynamic diameter of 4 micrometers or less) crystalline silica. The REL was extrapolated from occupational hygiene epidemiological studies, essentially all of which were based on in-plant PM4 crystalline silica measurements. No well-established ambient sampling technique for PM4 crystalline silica was available at the time that OEHHA adopted its REL. The personal samplers used for the National Institute for Occupational Safety and Health (NIOSH) Method 0600 in-plant sampling of employee exposure were designed for concentrations higher than ambient levels. The limit of quantification (LOQ) of PM4 crystalline silica on NIOSH 0600 filters was too high for the effective sampling of ambient air."

Jan 1, 2015

By M. A. Trevits, A. Ozment

"According to the Office of Surface Mining Reclamation and Enforcement, Abandoned Mine Land Inventory System, in 2013 there were 98 underground mine fires in nine states. This is considered to be an underestimate for the actual number of fires nationwide. Many mine fires are started by people burning trash where the coal seam or an abandoned coal mine is close to the surface. Other fire ignition sources include lightning and forest fires. Once ignited, a coal mine fire can easily spread into the remaining coal pillars and mine entries. Once established, the fire creates its own ventilation system supporting further combustion by drawing air down into the workings through unsealed mine shafts, fractures and surface subsidence depressions. As the coal left in the workings from the past mining operations burns, the mine void can collapse, causing subsidence and creating dangerous voids, damaging overlying surface structures and roadways. The products of combustion include smoke and noxious fumes such as carbon monoxide gas. These products are released to the atmosphere through fractures that develop within the ground surface, killing vegetation and creating serious health hazards (Richmond, 2017).Abandoned mine fires, if left uncontrolled, can burn for years and, in fact, one of the most wellknown mine fires in the United States is the mine fire in the Borough of Centralia, PA, that began on May 27, 1962. Reportedly, officials decided to clean up the local landfill for the upcoming Memorial Day holiday by burning the garbage on the site. Unfortunately, the landfill was located on the site of an abandoned strip-pit mine on the edge of the Borough (Dekok, 2009). The strip pit had been left open after being excavated around 1935 and was approximately 23 m (75 ft) wide and 15 m (50 ft) deep. It is believed that the lack of a properly constructed noncombustible shale barrier in the strip pit enabled the fire to spread to adjacent carbonaceous refuse material and then to nearby coal mine workings (PA DEP, 2017). As time went on, the fire grew and spread under the Borough and directly affected the residents despite various efforts to extinguish the fire by the state and federal governments (Fig.1). In 1984, a voluntary program was begun to move residents from their homes. Many accepted buyout offers for their properties and moved elsewhere and after leaving, their homes were demolished. In 1992, the state used eminent domain to take control of all the property within the Borough. In 2013, after years of litigation, the eight remaining residents were allowed to stay for as long as they lived. Today, only a few buildings remain within the Borough (Centralia, PA, 2014). This fire has been burning for more than 55 years."

Jan 5, 2018

By A. Noble

"Froth flotation circuits are widely used throughout the mineral processing industry for the concentration of fine particles. It had been estimated that nearly 2 Gt (2.2 billion st) of ores are treated globally each year using this versatile separation process (Fuerstenau, 1999). Due to the high feed tonnage, a large economic incentive exists for flotation plant operators to optimize the performance of this critical processing circuit. Prior to the 1950s, the optimization of flotation circuits primarily involved the manual adjustment of operating variables based on visual observation and sporadic sampling (Lynch, Harbort and Nelson, 2010). During the next several decades, however, the advent of improved on-line instrumentation coupled with the rapid development of high-speed microprocessors allowed the industry to develop more advanced control systems that could quickly adjust operational parameters in response to disturbances in ore characteristics and plant flows. These early online controls typically involved feedback loops designed to stabilize cell performance through the automatic manipulation of process variables such as pulp levels, gas rates and chemical dosages. The set-points for these controllers were often set by plant operators based on one or more operator objectives, such as maximizing throughput, recovery or grade. More recently, these regulatory controllers have been interfaced with high-level data display and management systems that provide operators with the ability to better optimize flotation plant performance based on mathematical models and rule-based algorithms (Greet, 2010).While tremendous strides have been made during the past several decades, even the most modern flotation plants are still faced with the long-standing question: “What are we trying to optimize?” From an operator perspective, some common responses include “Maximize tonnage of saleable concentrate” or “Maximize metals recovery at a customer-specified market grade.” These replies may or may not reflect those of management, who often focus on economic goals such as “Maximize profits for each operational unit” or “Maximize rate of return for all corporate assets.” Unfortunately, these high-level objective statements do not always translate well into practice due to the disconnect between plant operating protocols and product value. Attempts have been made by industry to overcome this issue using various types of optimization routines such as linear programming or other optimization engines. While this approach does have some merit, these blind routines require considerable input data and interpretational expertise and provide little or no fundamental insight that can be used to drive improvements in concentrator performance."

Feb 1, 2017

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 G. B. Amicucci

Golden Sunlight Mines Inc. operates an open-pit gold mine and cyanidation plant about 11km (7 miles) northeast of Whitehall, MT. Golden Sunlight is a subsidiary of Placer Dome US Inc. Mining is accomplished with conventional open pit drilling, blasting and hauling methods. The mining rate is about 102 kt/d (113,000 stpd). Gold occurs as fine-grained disseminations in a pipe-shaped breccia and in immediately adjacent country rock. The ore body is low grade, averaging 2 g/t (0.059 oz per st) of gold. The metallurgical plant uses conventional carbon-in-pulp (CIP) technology. Daily throughput averages 6.5 kt (7000 st). Recoveries are enhanced through a sand tailing retreatment facility while a preaeration process reduces operating costs. The low grade ore dictates that maximum mill throughput at the desired grind size be maintained. Therefore, in October 1988, an Armco Autometrics (now Denver Autometrics) particle size monitor (PSM) 400 was commissioned. The PSM 400 is an on-line instrument. It measures particle size and percent solids in a slurry stream. The PSM pulls its own sample, deareates the sample and passes it through diametrically opposed ultrasonic sensors. The unit uses ultrasonic sound to measure the deareated slurry stream's particle size and percent solids.

Jan 1, 1991

By Mark J. Zdunczyk

"Frac sand is industrial silica sand much like glass, foundry, filtration and blast sand. The sand must meet certain specifications set forth by the industry that consumes the product. The production and consumption of frac sand has experienced record growth in the last 10 years because of new oil and gas drilling, new horizontal well drilling, multi-stage fracturing and the stimulation of older wells that have little or no production. Frac sand is needed to “prop open” the fractures in the rock reservoirs to allow oil and gas to flow out more freely.According to the U.S. Geological Survey (USGS), the estimated production of frac sand in 2015 was 71 percent of the total production of industrial silica sand or 67.4 Mt (74.3 million st). This is a decrease of about 12 percent from 2014. However, the silica sand industry and other industry sources estimate only 50 Mt (55 million st) of frac sand were produced in 2015. In recent years both the USGS and industry studies have been very close in estimating the production of frac sand but with the recent downturn in frac sand production, perhaps, reporting to the USGS was not as accurate. These discrepancies may be that the USGS statistics are based on voluntary reporting by the industry and some companies report their approximate production, others may not. It is always difficult to obtain accurate production figures of any industrial mineral or construction aggregate operation as most companies tend to keep those figures somewhat confidential. It is certainly accurate to report that the production of frac sand had decreased since the last quarter of 2014 and through 2015. The oversupply of oil and natural gas has led to this decline in frac sand usage. Oversupply has idled drilling rigs and well completion activities. World Oil Magazine reports that 2015 was the worst year for rigs in a quarter century. The only wells being completed are those that have contract agreements to do so, others have been capped. Very few new wells are being drilled. Since about 98 percent of well completion is sand and water, the sand supply has caught up with the demand. There are some bright spots in the “oil patch” as the Permian Basin in Texas and the Woodford Shale in Oklahoma have kept pace somewhat with drilling and completion. It has been reported that the frac sand producers in the Brady-Voca, TX area are producing to nearly capacity. The northern frac sand producers like those in Wisconsin, Illinois and Minnesota are feeling the downturn because of the cost of shipping sand to these moderately active basins and plays. The “rule of thumb” is that freight is 2/3 and sand is 1/3 the cost."

Jul 1, 2016

By M. V. T. Da Silva, J. C. Harrison

Eldorado Gold Corporation of Vancouver, B.C. owns and operates three gold mines. The São Bento underground gold mine in Minas Gerais State, Brazil produced 105,907 ounces in1997. The La Colorada and La Trinidad open pit, heap leach mines in Mexico produced over 83,000ounces in 1997. With a deteriorating gold market plaguing the industry throughout 1997 Eldorado had to take critical measures at each mine to enhance gold production while lowering cash operating costs. Each mine had its own unique problems to confront. This case study will discuss three distinct courses of action taken at the three mine sites.

Jan 1, 1999

By F. Ikumapayi

Hydrogen peroxide production was measured during the grinding of a complex sulfide ore, and its oxidizing effect on solid surfaces was investigated using Fourier transform infrared spectroscopy (FTIR) with diffuse reflectance attachment measurement. In turn, an attempt was made to correlate the formation of hydrogen peroxide, surface oxidation and sphalerite flotation. Additionally, in order to predict and minimize detrimental production problems due to the recycling of process water in sulfide ore processing, the effects of major components of calcium and sulfate species present in recycled process water and the effect of temperature on sphalerite flotation were investigated through bench-scale flotation tests using complex sulfide ores. The significance of process water species in flotation was studied using tap water, process water and simulated water containing calcium and sulfate ions. Formation of hydrogen peroxide was revealed during the grinding of the complex sulfide ore, and its formation was counteracted by diethylenetriamine (DETA). The FTIR spectrum of the pulp solid fraction showed varying degrees of oxidized surface species, which are related to the concentration of H2O2 analyzed in pulp liquid. Bench-scale flotation using two different complex sulfide ores showed that sphalerite recovery is better in process water than in tap water. Flotation results also indicated a varied recovery of sphalerite at different temperatures in either tap water or process water.

By F. Djahanguiri

The U.S. Bureau of Mines is conducting research on underground stope leaching of metalliferous ores to minimize the environmental impact of ore processing on the surface and to maximize minable reserves. An aspect of this research is to minimize pregnant solution losses and/or groundwater contamination by leach solutions. Bulkhead design and construction are important issues for solution control and stope leaching economics. A reinforced concrete bulkhead was designed, constructed, and tested for solution control in an underground mine near Idaho Springs, CO. This paper presents the bulkhead design methodology and construction procedure.

Jan 1, 1995

By D. W. Alexander

Researchers from the U.S. Office of Mine Safety and Health Research (OMSHR) of the U.S. National Institute for Occupational Safety and Health (NIOSH) completed field trials during coal mine rescue contests using simulated gas detectors in place of placards. The gas monitor simulator (GMS) devices replaced static, paper placards to deliver gas concentration data. Eleven teams were observed during the field contest, which was approved by the Mine Safety and Health Administration (MSHA). GMS devices were given to three team members (the captain and both gasmen). Observation of teams revealed that team members changed behavior by acknowledging and sharing information more often while using the GMS. As a result of this research, it has been demonstrated that under the existing contest format, the newly developed GMS device may be used with no adverse impact on team contest performance. Furthermore, when GMS technology advantages are used, contest realism is improved. In the future, competency assessment may be incorporated.

Jan 1, 2012

By J. Marts

Underground longwall coal mining sections are operated as sealed gobs if the coal is prone to spontaneous combustion. Sealing along the gate roads during longwall face retreat limits the flow of fresh air (oxygen) into the gob and, thus, deprives the spontaneous combustion reaction of oxygen. In a project sponsored by the National Institute for Occupational Safety and Health (NIOSH), researchers at the Colorado School of Mines have used computational fluid dynamics modeling to simulate the flow of gases in sealed longwall gobs. The models were validated using measurements and observations from the field and demonstrate that targeted injection of nitrogen along the gate roads inby the face can be used to control the size and location of explosive methane clouds within the gob and to minimize or eliminate the explosion hazard resulting from the formation of flammable methane-air mixtures.

Sep 1, 2013

By Micah Nehring, MEHMET KIZIL, Farzad Sotoudeh, Amin Mousavi, PETER KNIGHTS

Production scheduling in underground mines is one of the most important and complex processes in maximising the economic value of an operation over the life of the mine. Due to increasing energy, transportation, processing and smelting costs and reducing water availability, the extraction of ore deposits through underground operations has become more expensive and challenging. A potential productive and efficient solution to mitigate these issues is to integrate pre-concentration systems into the existing mining system to increase ore grades through a preliminary process of rejecting some waste before sending the ore to the energy intensive mineral processing plant. Further benefit of such systems includes the utilisation of the waste and low-grade material in backfilling of open stopes to reduce the transportation costs and surface environmental impact such as reduction of CO2 emissions and waste transportation. The objective of this paper is to present a new mathematical model to optimise the production schedule of underground metalliferous mining operations in the presence of a pre-concentration system. The proposed model optimises the production schedule and sequencing of stopes within a sublevel stoping operation. The results of this study illustrate the potential economic benefits of using a pre-concentration system prior to a mineral processing operation as a result of increased net present value.

Nov 16, 2023

By Siddhartha Agarwal

The mining industry collects a significant amount of operational data. However, gleaning useful information from the terabytes of data is difficult, and not just because of the sheer volume of the data. Therefore, an automated tool was developed at the University of Alaska Fairbanks to go through data and apply sophisticated statistical and neural network techniques in order to identify the data streams that are important to a process. This paper presents results from the tool as applied to SAG mill data from a gold mine. The results were compared to results achieved earlier with available commercial modeling tools. The comparison indicates that there was little or no loss in performance by automating the very complicated process of neural network modeling. Therefore, the intent of the exercise, to examine if complicated modeling tasks can be automated, was realized. Mining Engineering, 2011, Vol. 63, No. 12, pp. 52-54. Official publication of the Society for mining, metallurgy and exploration, Inc.

Jan 1, 2011

By Richard E. Gertsch

If you believe that the goal of the space program should be a permanent, manned presence in space, then you believe in space mining. Historically, mining has been an integral part of the frontier. For the space frontier, mining is absolutely necessary. Any large-scale space facility must be built from materials mined in space. The reason is simple: the cost of getting material off the earth overwhelms all other costs. The cost of launching a pound of material from earth into low earth orbit ranges from $5000 to $10,000. Multiply this number by three to get to geostationary orbit. With the added expense of landing on the moon, an object is worth more than its weight in gold. Most space projects are impossible if materials must be hauled out of earth's enormous gravity well. For example, habitats (large structures in free-fall that simulate earth's gravity) and massive solar power satellites will take millions of tons of material to construct. Transportation economics alone dictate space as the source for oxygen, construction materials, and metals, among others. Space mining is not concerned with introducing materials for terrestrial use. The need for materials in space is infinite. The challenge for the mining industry is enormous.

Jan 1, 1991

By Michael F. Roach, Joseph K. Cavey, Gary E. Taylor

A rigorous horizontal drilling and chemical grouting program was specified beneath the Hollywood Freeway (U.S. Route 101) section of Los Angeles Metrorail Contract C-311.Twin 6.67-m (22-ft.) diameter starter tunnels were to be conventionally mined through amixed alluvial and bedrock face consisting of silty sand, gravel, and weathered sandstone and siltstone of the Topanga Group. The contact between the alluvium and bedrock dipped toward the Crossover Excavation where the horizontal drilling and grouting operations were performed. The intent of this grouting program was to stabilize the mixed face to minimize ground loss and surface settlement, and to reduce groundwater inflow into the tunnel headings. Given the highly variable mixed face conditions, horizontal drilling up to 86 m (284 ft.) resulted in upward trending trajectories which likely followed the bedrock contact. Chemical grouting was performed in a primary, secondary and tertiary, three dimensional sequence. Evaluation of the primary and secondary grouting parameters indicated where tertiary grouting was required. Grouting pressures induced a small rock failure at the tunnel heading as well as increased stresses on the tiebacks of the excavation.

Jan 1, 1997

By Igor Gonzales G.

The Southern Peru Copper Corp. (SPCC) recently built an integrated copper project consisting of dump- and heap-leaching operations at its mine complex in Peru. The pregnant leach solution (PLS) containing the solubilized copper from the leaching operations is processed in a new solvent extraction/electrowinning (SX/EW) facility to produce high-purity cathode copper. The dump leaching and SX/EW facilities are located near the Toquepala mine site. The crushing and heap-leaching operation is located at the Cuajone Mine. The pregnant leach solution from Toquepala and Cuajone is pumped 35 km (22 miles) to the SX/EW plant at Toquepala. The SX/EW plant consists of three trains of solvent extraction (SX), a tank farm area and an electrowinning (EW) facility. The solvent extraction plant has a total PLS flow capacity of 3,210 m3/hr (113,360 cu ft/hr). The electrowinning facility has an expected long-term production capacity of 97 t/d(107 stpd) or about 35 kt/a (38,500 stpy) of cathode copper. However, present production exceeds the expected long-term by about 20%.

Jan 1, 1996

By J. L. Ellenberger

The U.S. Bureau of Mines has cooperated with Cyprus Casa Grande Corporation Cyprus Casa Grande Mine, Cas a Grande, Arizona, since 1988 to assess the hydrology of an in situ leaching test facility. This work has resulted in an in situ design for leaching copper oxide ore that takes advantage of the increased mineral access associated with poor quality rock surrounding mine drifts. Blasting and bulkheads are used to produce readily-leachable rubble and contain and control solution movement, respectively. The design reduces the need for handling solution under high pressures in an injection/recovery system for in situ leaching of underground ore bodies. Early work at the site recognized a stress redistribution zone and increased transmissivity near drifts. Fracture data from a corehole oriented parallel to the dip of the ore body indicated an increase in fracture frequency around drifts a distance of 21 m (70 ft) away from the 5 m (16 ft) diameter drifts.

Jan 1, 1994

By Jian Liu

The dissolubility of a natural sphalerite (ZnS) in the entire pH range was theoretically calculated, and its practical dissolution in an aqueous solution at different pH values in an inert environment, together with its surface properties after dissolution, was fully investigated. The results of the investigation indicate that the total concentration of Zn (CZnT) decreases significantly with the increase of pH value, while the pH value is set below 8; however, it reverses when the pH value reaches 8. Such a tendency is similar to that of the theoretical calculations, although the experimental CZnT were much higher than those of the theoretical calculations. The X-ray photoelectron spectroscopy (XPS) of the sphalerite surface after its dissolution under alkaline solution shows that a polysulfide (Sn 2-) surface layer with a binding energy (BE) value of 162.96-163.25 eV is present on the surface, and the percentage of Sn 2- increases significantly with an increase in pH value; the undissolved and dissolved sphalerites under the acidic solution have a negligible difference in S2p peaks. The surface S/Zn ratio of all dissolved sphalerites shows a marked Zn enrichment and S deficiency. An atomic force microscope (AFM) view of the sphalerite surface, after its dissolution under the alkaline solution at a pH of 12, shows that the surface is significantly different in morphology from that of the undissolved one.

May 1, 2012

By N. D. Policow, J. S. Orphanos

D.A. Dahlstrom In the paper, a comparison was made between flowsheets using the screen bowl centrifuge and disc filters, respectively, as the primary dewatering device. The authors very effectively show that by raising feed temperature, mechanical dewatering is enhanced through reduced viscosity of the water. When a final coal moisture of 10% is required, the net effect of heating the feed is a reduction in thermal requirements because of the lower evaporated load on the dryer. The flowsheet comparison on this, however, was not completely correct. Disc filters do not generally utilize enhanced mechanical dewatering through increased temperature. Horizontal belt filters, through the optimal use of steam heating of the filter cake, have shown significant cost reductions over disc filters where steam is not used. In addition, the authors forgot to mention that there is a certain fraction of the feed that is so fine that it cannot be recovered by the centrifuge economically. That is the function of the filtration device shown in Fig. 4. In subbituminous pipeline coals, this fraction represents more than 10% of the feed. Even after flocculation and belt pressing, the moisture content in the fine fraction is 30%-40. Recent tests on a subbituminous pipeline coal slurry, compared an Eimco-Extractor horizontal belt filter with the screen bowl centrifuge flowsheet shown in Fig. 4. Mechanical dewatering was enhanced through the use of a steam dry zone after the initial dewatering zone. Vacuum pump horsepower was reduced by more than 50% through the use of condensors, and heat recovery was utilized to minimize thermal costs. Thermal drying to 10% moisture by weight was required in both flowsheets. The 0.5 wt% fines in the filtrate were flocculated and recycled to the filter, thus eliminating the belt press and solids mixers. When the three major operating costs (which normally account for 50%-75% of the coal operating costs) of steam, electricity, and flocculants at current prices were calculated, the flowsheets utilizing the Eimco-Extractor had cost savings vs the centrifuge flowsheet of 89¢/t (81o; per st) of surface dry coal. This advantage increases with increasing thermal and electricity prices. I congratulate the authors for the strides made with the screen bowl centrifuge. However, filtration flowsheets continue to be improved and their simplicity and low thermal and electrical requirements should not be so quickly dismissed. ? Reply by N.D. Policow From a technical standpoint, a number of extensive test programs have demonstrated that by raising the feed temperature, mechanical dewatering is enhanced whether it be centrifuges or filters performing the separation. Economic constraints usually become the over-riding issue. If an inexpensive source of thermal energy is available, i.e., waste steam, etc., the approach becomes commercially acceptable. For the specific case of coal slurry pipelines, since the dewatering plants will be located close to power generation stations, the preheating approach becomes especially attractive. The cost comparison shown in Fig. 7, which was prepared by a major West Coast engineering firm, contrasted screen bowl centrifuges and disc filters. In both alternatives, a thermal dryer was specified to produce a contract moisture of the final product. Sizing of the thermal dryer on the screen bowl alternative was substantially smaller than that of the filter, since the screen bowl was credited with a four to six percentage point decrease in product moisture compared to the disc. This comparison was made at ambient temperatures and reflected solely the mechanical dewatering capabilities of the two devices. No preheating of the feed was included in this particular comparison. Early generation screen bowl centrifuges operated under the principle of maximum bulk tonnage throughput. Second and third generation machines have followed the trends dictated by the coal industry calling for higher one-pass recoveries than previously demanded. The current generation of high-speed, long-bowl centrifuges permit recoveries of ultrafine solids directly comparable to commercial filter operation. On typical coal preparation plant feeds with nominal 600 E. an X 0 (28 mesh X 0) clean coal, recovery levels in excess of 99% are now obtained. The material that does escape the centrifuge and reports to the main effluent is typically -10 µm, high ash material. We have documented substantial beneficiation effects in screen bowl centrifuge performance with the cake product containing lower ash levels than the feed. On the referenced pipeline, coal tests performed on Western subbituminous coal, we found that the percentage of -10 µm material in the feed was six to eight times greater than normally encountered on eastern Appalachian seams. Our 45-t/h (50-stph) production centrifuge was never set up to maximize recovery. It was used as part of the two-stage dewatering circuit that had been chosen by designers of the proposed pipeline. Recoveries up to 95% were recorded. With field adjustments, that performance could most certainly have been improved. In contrast, manufacturers of the horizontal belt filter provided a small pilot-scale unit that operated on a side stream at the test facility. Numerous combinations of chemical additions were evaluated to determine those that had the best impact on filter performance. Whereas the screen bowl centrifuges operated without chemical addition, producing a dry, fluffy cake, the belt filter required two stages of chemical addition to attain satisfactory performance and high recovery levels. On the two-stage circuit that incorporated a belt press as the secondary

Jan 12, 1983