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By James R. Evans

Forecasting demand is an art as well as a science, and much personal judgment is required. National forecasts made for sand and gravel, crushed stone, and/or aggregate may be misleading or unhelpful locally. This is because of significant variation in demand within different geographic and/or political areas in the United States, and/or the use of an inadequate data base and forecasting methodology. The best forecasts may be made for local or regional market areas, irrespective of geographic or political boundaries, provided a proper data base is available. The Bureau of Mines compiles detailed statistics on commodities sold or used in the construction industries and, therefore, is in an advantageous position to make national aggregate demand forecasts.

Jan 1, 1978

By G. Bonifazi

The study of minero-petrographical characteristics and the subsequent textural and structural characterization of an ore mineral represents the first step of each industrial processing whose aim is the beneficiation of each valuable mineral phase present inside the ore. Analytical, mineralogical and petrographical, chemical and multispectral image analyses based investigations, applied to eclogitic ore samples deriving form "in situ" sampling campaigns, were applied. These procedures enabled to point out some textural and structural aspects characteristics of ore litotypes belonging to eclogitic-amphibolitic dikes. Such dikes are characterized by a paragenesis constituted mainly by siliceous gangue and accessory "useful titanium minerals" as rutile [TiO2], "pseudolilmenite", ilmenite [FeTiO3] and sphene [CaTiSiO5]. In the beneficiation process applied to ore s is of preliminary importance to establish a strategy in order to obtain a recovery of high quality "mono-minerals concentrates" as rutile, "pseudolimenite", ilmenite and phene. To reach this goal is thus necessary to develop a preliminary study of the textural, structural, petrochemical and minerochemical characteristics of the samples. Different ore samples (eclogitic rocks), resulting from sampling campaigns carried out in the Piampaludo area (Sassello district: Savona, Northern Italy), are examined.

Jan 1, 1994

By G. E. Viens

The electric arc furnace has characteristics which make it attractive for a number of metallurgical applications. Some of these characteristics are: high thermal efficiency, the possibility of attaining very high temperatures, low off-gas volume compared to fuel-fired furnaces, no impurities are introduced by the heat source, and impurities in only minor amounts are introduced by the electrodes. It also has disadvantages, the chief ones being the relatively high cost of electrical energy compared to fossil-fuel energy and the fact that, when oxide ores are smelted using carbon as reductant, the off-gases emitted are rich in carbon monoxide. As in many other pyrometallurgical processes, fumes and dust are emitted from melting or smelting operations. In many installations, some or all of the off-gases are flared, thereby wasting their energy and contributing to atmospheric pollution. During the last eight years, a shaft-electric furnace has been under development at the Mines Branch, Department of Energy, Mines and Resources, Ottawa, Canada. This project was initiated to try to overcome, or at least minimize, the disadvantages of the electric furnace. Experience on other projects, prior to the beginning of this program, had indicated that preparation of the charge materials, for example by sizing raw ore, sintering concentrates and crushing and sizing the sinter, or agglomerating concentrates into uniform-sized pellets, could make a substantial contribution towards achieving success in arc-furnace smelting projects; This entire

Jan 1, 1971

By Levent Ozdemir

An extensive study involving laboratory testing and computer modeling has been performed to assess the technical and economic feasibility of utilizing the recently developed minidisc cutters on roadheaders for hard rock mining. The results show that heavy duty roadheaders fitted with minidiscs can excavate hard rock formations at acceptable production rates and cutter costs. This paper presents and discusses the results of this study together with the ongoing developmental efforts of this technology, which include laboratory testing of a roadheader cutting drum with minidiscs and full scale field testing of a machine in hard rock

Jan 1, 1995

By Kanhaiya Mishra, Phanil. K. Mandal, S. K. Behera, P. S. Paul, Prashant Singh, C. N. Ghosh

The techno-economic and social benefits of cemented paste backfill (CPB) resulted in its wide acceptance by the mining industry. The Ordinary Portland Cement (OPC) remains the key binder but to diminish its economical constraints, suitability of alternate binders has been examined worldwide. The present study aimed to investigate the effect of partial replacement of OPC with fly ash on the CPB’s strength and to determine the most optimal mix to achieve the required strength (1 MPa at 28 days of curing) at the most cost-effective way using the Bayesian network (BN). The CPB mixes were prepared at 72 wt.% solid concentration with mill tailings (87–91%), OPC (6–13%), and fly ash (0–4%), and instantly after mixing, fresh (slump, bleeding, density) CPB properties were measured. The strength was tested at 7, 14, 28, and 56 days of curing and initially analysed through traditional model. The traditional models follow the aleatory principle and are considered not appropriate for geotechnical engineering. Hence, the BN model was developed and tested. The reliability of two classifiers in learning model structure was compared which gives Naïve Bayes as the highest reliable tool. The CPB’s strength is most sensitive to the OPC content. The most consistent mix(s) is mill tailings: 87–88%, OPC: 9–11%, fly ash: 1–4%. Adding fly ash at 89–91wt% mill tailings possesses high failure probability of the CPB. The collinearity test indicates that the fines percentage and chemical composition of CPB’s ingredients are highly correlated with its slump, bleeding, and strength development.

Jul 14, 2022

By E. M. Wilde

Through the USGS's National Coal Availability program, coal resource appraisals have been completed for three 7.5-minute quadrangles (Willow Crossing, Colstrip East, Colstrip SW) in the Powder River Basin area of southeastern Montana. Available coal reserves (original reserves minus tonnages affected by current restrictions) vary from 44 to 70 percent of the original reserves. Major restrictions impacting each area also vary. In each area, one or two beds contain most of the reserves, but up to eleven beds contain available coal. The main beds in completed studies are the Knobloch, Rosebud, Sawyer and Flowers-Goodale. Three additional areas (six 7.5-minute quadrangles) are in preparation.

Jan 1, 2001

By HONGWEI YANG, Lili Zhang

The oxidation behavior of copper smelting slag under non-isothermal conditions was studied by thermal analysis. The results indicate that the copper slag is mainly composed of fayalite ( Fe2SiO4) and magnetite ( Fe3O4). The oxidation behavior can be divided into two reaction stages with the increase in temperature; the first stage is the oxidation of fayalite to magnetite, and the second stage is the oxidation of magnetite to hematite. The two reaction stages cannot be strictly separated; that is, the reaction of fayalite is not complete, and magnetite has begun to transform into hematite. Based on the TG (thermogravimetric) curves, the ABS (Achar–Brindley–Sharp–Wendworth) differential and the Coats–Redfern integral methods were employed to investigate the oxidation kinetics of copper slag during the continuous heating process. The oxidation of fayalite into magnetite and amorphous silica phases occurs mainly in the temperature range of 673 to 1083 K. The activation energies calculated by the two methods are 193.69 and 195.52 kJ mol− 1, respectively. The reaction is consistent with Avrami–Erofeev equation, and the mechanism of oxidation is random nucleation and growth. The oxidation of magnetite to hematite occurs at 1083–1303 K. The activation energies are 308.79 and 328.77 kJ mol− 1, respectively. The mechanism conforms to the Jander equation and is controlled by the two-dimensional diffusion.

May 16, 2022

By Ihsan Berk Tulu, Haochen Zhao, Deniz Tuncay

This paper proposes a new method to estimate the percentage of load carried by the gob in underground coal mines using a new parameter that introduces the site-specific overburden geology. The new parameter was defined as the total strong layer thickness (tstr) that represents the strength and stiffness of the overburden with a single value. Twelve field measurement case studies from 11 different U.S. longwall mines with different overburden geologies were used to develop the new methodology. 2D numerical models of these case studies (and additional parametric runs with different panel widths) were verified against field measurements such as surface subsidence and stress. Statistical analyses using the model results were conducted for a loading model with the new tstr parameter as one of the variables. The new methodology was found to have a coefficient of determination (R2) of 85% when compared to the field measurements and the parametric models. The method was then tested for practical implementation for pillar design. The percentages of load carried by the gob as estimated by the new method were implemented into the LaModel program, that is commonly used in the coal industry. The results obtained from LaModel were compared to the available field stress measurements, and the new method implemented into LaModel was found to give successful results.

Jul 18, 2022

By R. D. Doepker

The dissolution of metals from various metal-mine tailings has been studied through a series of submerged tailings batch tests at U.S. Bureau of Mines laboratories. Tailings selected for this study included both reactive (as determined by column leaching studies) and benign tailings. Metal mobilization in aerated (97 pct saturated with oxygen) samples appeared to be consistently greater than metal dissolution from stagnant (79 pct or 70 pct saturated with oxygen) waters. In the early weeks of the study, sulfate concentrations increased with solid-liquid contact time, while calcium dissolution remained nearly constant. Metal concentrations varied in relation to solid-liquid contact time and aeration. Leachate pH appeared to be nearly independent of solid-liquid contact time for basic tailings. Reactive tailings having both a submerged and a surface component demonstrated increased metal mobility.

Jan 1, 1990

By R. L. Virta

Ball Clay -- Four companies - H.C. Spinks Clay Co. Inc. (owned by Lhoist Group), Imerys Group (formerly Kentucky-Tennessee Clay Co.), Old Hickory Clay Co. and Unimin Corp. - mined ball clay in four states during 2010. Production, based on preliminary data, was 910 kt (1.11 million st) with an estimated value of $42.9 million. That was a 10-percent increase in tonnage from 831 kt (916 million st) with a value of $37.7 million that was produced in 2009. Tennessee was the leading producer state with 61 percent of domestic production. It was followed by Texas, Mississippi and Kentucky. About 70 percent of production was airfloat, 20 percent was crude and 10 percent was water-slurried.

Jan 1, 2011

By E. R. Mueller

The natural lives of machines and components vary tremendously! Maintenance managers struggle constantly to maximize their equipment lives while minimizing their maintenance costs, but they normally lack the tools and techniques they need to do this properly. This paper proposes a methodology based on probabilities of failure and expected values for repairs that recognizes the variation among individual machines and components as well as the high costs associated with catastrophic failures. It enables a user to determine the optimum change-out intervals for many types of equipment. The approach proposed here is sophisticated enough to be reliable but simple enough to be applied by the maintenance staff on the shop floor. It will complement existing preventive and predictive maintenance programs.

Jan 1, 1995

By M. Tanaji

Over the last many decades, a significant amount of research has gone into the domain of slurry transport. However, design engineers still face many challenges with respect to prediction of pressure drop, critical velocity and other design parameters as a function of Solids % and Particle Size Distribution (PSD). The industry requirement is to transfer the slurry at the maximum concentration as possible (above 30% (volume %)) to make slurry transport more economically viable and to reduce water consumption. To facilitate the design and scale-up of slurry transport in pipelines and in process plants, there is a need for a correlation that can predict slurry pressure drops over a wide range of operating conditions and physical properties of different slurries. The objective of this study is to overcome the limited range of applicability and validity of existing correlations and to develop a generalized but more rigorous correlation applicable to a wider range of slurry sys-tems. The existing Wasp et al. (1977) method is based on multi-phase flow modeling approach. This study attempts to modify this approach by considering material-specific values of Durand?s equation co-efficient and by defining flow regimes based on particle Reynolds number. When compared with experimental data, the modified Wasp method proposed in this study predicts the pressure drop for slurry flows more accurately than other available correlations. Also, the pro-posed method requires minimal test/experimental data for a particular slurry system and can be extended over different input conditions. An iterative computer algorithm is developed to calculate the criti-cal settling velocity and pressure drop in a pipe as a function of Solids % and PSD. The solution method can easily be implemented in de-signing slurry pipes, design validation, and studying the different slurry transport scenarios. The modified method can also be extended to accurately predict pressure drops in dynamic pressure flow networks used in commercial process simulators.

Feb 23, 2014

By Bill S. Taylor

Dutch State Mines [D.S.M] introduced the Heavy Medium Cyclone into the United States for cleaning fine coal about three decades ago. Since that time the general industry practice has been to deslime the raw coal at 28 Mesh (0. 59mm) size. The plus 28M material is fed to the Heavy Medium Cyclone for cleaning, and the 28M x 0 fraction is processed by other means (e. g. flotation or hydrocyclones). This approach recognized that 28M was the smallest size particle that could be easily rinsed on vibratory screens without excessive loss of magnetite, and without blinding of sieve bend and vibratory screen decks. Another reason for the 28M de-sliming was to avoid excessive contamination of the media with non-magnetic coal, shale, or clay fines. The most undesirable of these contaminants is the sub-micron size clay particles (2) that greatly increase the viscosity of the media and reduce the numerical maximum level that the media specific gravity can obtain due to the lower specific gravity of clay with respect to magnetite. The higher the fugitive clay content, the more severe the preceding problems become. During the last 30 years, many conventional Heavy Medium Cyclone Plants have been built throughout the world. In the United States, the initial cyclone plants were confined to the production of high quality metallurgical coal where lower gravities of separation were required than could be obtained from the conventional hydraulic or air separation processes. In recent years a large and ever-increasing number of preparation plants producing steam coal have started utilizing Heavy Medium Cyclone technology due to the environmental pressures being encountered to produce low sulphur coal. Due to the inherent characteristic of many coals of having a lower pyritic sulphur content at lower specific gravity fractions, many applications and markets are appearing for separating steam coals at much lower specific gravities than have been historically normal in the United States. Therefore. Heavy Medium Cyclones are being utilized to a much greater degree in this field, due to the flexibility of low separating gravity ability coupled with high efficiency when high percentage of near gravity material is present.

Jan 1, 1978

By Toby Mayo, Tassos Grammatikopoulos, Massoud Aghamirian, MARK FEDIKOW

The Zoro pegmatite project in east-central Manitoba occurs 20 km east of the historic mining town of Snow Lake. A composite sample (Master Comp) was prepared fromthree pegmatite zones within Zoro Dyke “D1” including the North, Central, and South Zones for mineralogical analysis and heavy liquid separation (HLS). The mineralogical examination was conducted on a subsample crushed to ca. P80 of 600 μm to determine the overall mineral assemblage, liberation of spodumene, and assess the potential recovery of spodumene by flotation. XRD and QEMSCAN results show that the sample consists of spodumene (10.5%), quartz (29.3%), plagioclase (29.0%), K-feldspars (21.3%), micas (5.1%), tourmaline (2.9%), and Fe-Mn-phosphates (0.1%). Spodumene is well liberated (88%), but also forms complex particles (7%), and middlings with quartz (4%). Liberation of spodumene increases from 81 in the + 600 μm to 95%in the − 106 μm size fraction. Liberation of quartz, feldspars, and micas account for 89%, 94%, and 83%, respectively. Electron probe micro-analyses and LA-ICP-MS showed that the average Li concentration is 3.7% in spodumene, 2196 ppm in micas, 1001 ppm in tourmaline, and 115 ppm in K-feldspars. Thus, spodumene accounts for 96%, micas 2%, Fe-Mn phosphates 1%, and both K-feldspars and tourmaline for < 1% of the total Li in the sample. The mineralogical data indicate the potential to recover spodumene by flotation with minimal Li losses due to other than spodumene carriers. Heavy liquid separation was conducted on the Master Comp which was crushed to − 6.4 mm, while the − 600 μmfractionwas removed fromthis test. The coarse fraction − 6.4mm/+ 600 μmwas subjected to HLS tests with eight heavy liquid-specific gravity cut-points (2.65 to 3.10 g/cm3). HLS indicates that it is possible to produce a high-grade lithium concentrate (close to 6% Li2O) after the rejection of iron silicates with magnetic separation.

Sep 16, 2020

By Kenneth L. Maloney

Ten small and intermediate-sized [11 GJ/hr to 264 GJ/hr (10,000 lb/hr steam to 250,000 lb/hr steam)] coal-fired boilers in the upper Midwest have each been tested on both a bituminous eastern coal and a subbituminous western coal. The purpose of this study was to determine the feasibility of substituting western subbituminous coal for eastern bituminous coal as a means of reducing the SO x emissions from this class of boiler and to demonstrate the feasibility of greatly expanded western coal utilization as a means of reducing the use of oil and gas. The scope of this study was such that the representative boiler types were tested on both eastern and western coal for a period of time sufficient to completely characterize their individual emission and operational characteristics.

Jan 1, 1977

By M. SIDDARAJU, Rameshwar Sah, Satendra Kumar, Arvind Jaiswal

The study explores a novel process to sinter porous iron ore with improved productivity and quality. The iron ore is pre-processed with calcined lime to temporarily close pores, preventing water absorption during granulation. This enhances reaction kinetics and early slag formation during sintering, resulting in significant improvements in sinter productivity, product yield, and cold strength property.

Feb 28, 2022

By Ross W. Smith

In recent years there has been a considerable amount of research work done relative to the effect of pretreatment and aging in water on the surface properties of both simple metal oxides and more complex oxides such as the silicate minerals 1-6. Of particular interest is the work of Somasundaran6 who states that after preparing minerals by size reduction and washing with dilute acids "... it is essential to treat it (the mineral) with water in order to remove any effects of leaching itself." Somasundaran also states, "... it is advisable to use a solution close to the point of zero charge for conditioning purposes." Parksl notes that, "Dehydration, dehydroxylation, and increased crystallinity can be expected to decrease the PZC. The presence of anionic impurities or of pH-independent potential determining ions will decrease the PZC. Cationic species will increase the PZC." Healy and Jellett4 believe that in the Zn0-water system "the surface charge of Zn0 in water and each pH is determined by the concentration and adsorption of each hydrolyzed (charged and uncharged) Zn(II) species." Finally, according to Parks 2, "The PZC of an unaltered com¬plex oxide in a system devoid of specific electrolytes is approximately the average of the PZC&apos;s of its component oxides... Equilibration with water results in loss of mono and divalent cations by exchange with H+, thus a loss of influence on the PZC by those cations, i.e., a shift in the PZC with time in the direction of that remaining oxide. The present paper investigates the change of point of zero charge (PZC) of a number of simple oxides and several complex oxides as a function of aging time in water. In some cases acid pretreatment of minerals was performed. However, in most cases the minerals were not acid pretreated. In several systems pH change as a function of aging time in water was monitored.

Jan 1, 1972

By Michael Murphy, Gamal Rashed, Brent Slaker

Pillar stability continues to be a significant concern in multiple-level mining conditions, particularly for deep mines when pillars are not stacked or the thickness of interburden between mining levels is thin. The National Institute for Occupational Safety and Health (NIOSH) is currently conducting research to investigate the stability of pillars in multiple-level limestone mines. In this study, FLAC3D models were created to investigate the effect of interburden thickness, the degree of pillar offset between mining levels, and in situ stress conditions on pillar stability at various depths of cover. The FLAC3D models were validated through in situ monitoring that was conducted at a multiple-level stone mine. The critical interburden thickness required to minimize the interaction between the mining levels on top-level pillar stability was explored, where the top level mine was developed first followed by the bottom level mine. The model results showed that there is an interaction between numerous factors that control the stability of pillars in multiple- level conditions. A combination of these factors may lead to various degrees of pillar instabilities. The highest degree of local pillar instability occurred when pillar overlap ranges between 10 and 70%. On the contrary, the highest degree of stability occurs when the pillars are stacked, the underlying assumption is that the interburden between mining levels is elastic (never fails). Generally, for depths of cover investigated in this study, the stability of top-level pillars shallower than 100 m (328 ft) or with interburden thicknesses greater than 1.33 times the roof span—16 m (52.4 ft) in this study—does not appear significantly impacted by pillar offset. The results of this study improve understanding of multiple-level interactions and advances the ultimate goal of reducing the risk of pillar instability in underground stone mines.

Jul 27, 2022

By W. C. Hellyer

In an autogenous grinding circuit in which feed at approximately nine inches top size is reduced to a size suitable for subsequent processing, the build- up of a "critical size" fraction in the media causes problems. A "critical size" fraction has been defined as, "media too small to effect reduction by impact grinding of ore coarser than a quarter of an inch and too large to be broken by the largest size of media in the charge. 9, (1) The buildup of a "critical size" fraction reduces the capacity of the mill, increases the grinding power requirements per ton of finished product, and generally produces a finer grind than is desired. It is general practice to overcome this problem by the addition of large diameter steel balls to the grinding charge. This has certain disadvantages, such as; (i) an increase in mill liner wear; (ii) wear on the steel balls, and; (iii) some loss in flexibility in grinding circuit operations resulting from difficulties in removing the steel balls by means other than by grinding out.

Jan 1, 1970

By William Watson

Coal production in the United States in 2010 increased to a level of 960 Mt (1,085.3 million st), according to preliminary data from the U.S. Energy Information Administration (EIA), an increase of 1 percent, or 9.43 Mt (10.4 million st) above the 2009 level of 975 Mt (1,074.9 million st) (Table 1). In 2010, U.S. coal consumption increased in all sectors except commercial and institutional, while total coal stocks fell slightly for the year. Coal consumption in the electric power sector in 2010 was higher by 4.5 percent, while coking coal consumption increased by 37.9 percent and the other industrial sector increased by 7.1 percent. The commercial and institutional sector, which prior to 2008 had been called the ?residential and commercial? sector and is the smallest of all the coal-consuming sectors, declined by 3.1 percent in 2010. (Note: All percentage change calculations are done at the short tons level.) U.S. coal exports increased from the 2009 levels due mostly to higher demand for metallurgical coal, while coal imports decreased for a third year in a row. The increase in coal consumption for electric generation during the year was the consequence of improving domestic economic conditions further bolstered by a cold winter and warm summer in important coal-consuming regions. Preliminary data show that total generation in the electric power sector (electric utilities and independent power producers, including useful thermal output) in the U.S. increased in 2010 by 4.2 percent. Coal-based generation also increased, resulting in a 38-Mt (42-million st) increase in coal consumed in the electric power sector. Coal use in all the sectors other than the electric power sector increased by 13.9 percent to a level of 65.9 Mt (72.7 million st).

Jan 1, 2011