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By Gerald H. Luttrell, Seyed Hassan Amini, Aaron Noble

One of the most important processing engineering tools for designing mineral processing facilities is linear circuit analysis. This technique, originally conceived and developed by Meloy, Williams, and Fuerstenau nearly four decades ago, provides fundamental insights regarding how unit operations interact and respond when arranged in multi-stage processing circuits. Researchers have successfully utilized this tool to improve the operating performance of industrial processing circuits incorporating coal spirals, magnetic separators, mineral spirals, and eddy current separators. More recently, advanced versions of this tool have also been developed to provide a standardized framework for circuit mass balance calculations, to output exact analytical solutions to mass yield and value-based efficiency expressions, and to estimate uncertainty propagation in separation circuits. This article reviews the historical development of linear circuit analysis, describes how the technique has evolved to address more complex circuit design problems, and presents industrial case studies that highlight the importance of this process engineering tool.

By Veerendra Singh, NILAMADHABA SAHU, ARIJIT BISWAS

Manganese (Mn) ferroalloys are chiefly consumed in the steelmaking process as a deoxidizing agent or as an alloying element to produce high-quality steels. These alloys are typically produced in a submerged arc furnace using coke, fluxes and manganese ores of a specific manganese/Fe (Mn/Fe) ratio. Preferred-grade manganese ores should have Mn content greater than 46 percent and Mn/Fe content greater than 5 to produce commercial-grade, high-carbon ferromanganese [1]. Selective mining of high-grade Mn resources has created a scarcity of these resources, which is emerging as a major challenge for the manganese and steel industry. Manganese ore resources are mainly distributed in South Africa, with about 32 percent; Ukraine, with about 17 percent; Australia, with about 17 percent; and Brazil, India, China, Gabon and Mexico, with lesser amounts.

By Ning Wang, Tengfei Guo, Wanyan Li, Hanjie Wen, Hannian Gu, Zehai Li

Bauxite residue (red mud) is an alkaline waste derived from the industrial process for extraction of alumina from bauxite ore. Some bauxite residues contain considerable concentrations of critical metals, for example, rare earth elements. Lithium in red mud was also reported as a potential resource. In the current study, a Li-rich red mud was leached using acetic acid to investigate the leaching behavior of lithium followed by neutralizing with hydrochloric or oxalic acid. By neutralizing red mud using diluted hydrochloric acid (0.01 mol/L), 58.04–60.27% of lithium was leached using 25% acetic acid at 95 °C for 60 min. In the meantime, more than 95% of sodium and 85% of calcium were also dissolved in the leachate solution. While oxalic acid (0.5 mol/L) was used to neutralize red mud prior to acetic acid leaching, lithium performed lower leaching efficiencies (42.41–46.88%) in comparison of using of hydrochloric acid–neutralized red mud. Nevertheless, these leaching efficiencies of lithium were close to that of calcium and much higher than those of sodium under the condition. In this study, 25% (v/v) of acetic acid, at 85 °C for 60 min, was demonstrated as optimum conditions for lithium extraction from oxalic acid–neutralized red mud using acetic acid. The results would be useful and of interest for lithium recovery and purification from red mud.

By İbrahim Çınar, Hakan Özşen

Mine workers in heavy and dangerous work are under several physical risk factors, for example temperature, humidity, noise, vibration, lighting and air velocity. Thermal comfort includes parameters such as air temperature, air humidity, air flow rate, radiant heat, metabolic rate and garment insulation. In this study, thermal comfort conditions were evaluated using thermal comfort indices defined as predicted mean vote (PMV) and predicted percentage dissatisfied (PPD) which were determined by measurements taken from an underground coal mine for approximately 100 days. Although the metabolic rate (light work) was kept at 2 met, it was found that predicted mean vote ranged between − 2.58 and 1.68. The predicted percentage dissatisfied index was found to reach 95%. According to the results, it can be seen that thermal comfort may have negative effects on occupational health and safety. The change in thermal comfort index values in the Soma Underground Coal Mine was investigated in detail and the reasons for the changes were determined. Furthermore, determining the optimal working environment for the mine workers was also an aim of this study.

By SUHAINA ISMAIL, NORLIA BAHARUN, SHAIK ABDUL RAHMAN, WAN NUR SYAFIQAH ANUAR, MOHAMMAD REZAEI ARDANI

Refractory gold ore contains sulfide minerals like pyrite, chalcopyrite and sphalerite that are difficult to be directly leached by cyanidation or by lixiviants such as thiourea and halides. In such cases, it is necessary to perform oxidative pretreatment of the ore to oxidize the sulfide matrix, and gold particles can be exposed to the solution during the leaching process [1]. In recent years, hypochlorite and chloride solutions have been introduced as alternative materials for hydrometallurgical methods of gold extraction instead of cyanide solution [2]. A previous study by Hasab et al. [3] reported that the gold dissolution rate in hypochlorite solution was higher than in the cyanidation process, due to the presence of hypochlorous acid (HOCl) as a strong oxidizing agent. In a hypochlorite leaching system, the change in pH can influence the presence of oxidant species in the solution: the hypochlorite ion (OCl−) is stable in pH greater than 7.5, HOCl can be found in pH between 4.0 and 7.5, and aqueous chlorine (Cl2 (aq)) is the predominant oxidant when pH is below 4.0. As HOCl is the most effective oxidizing agent for gold extraction, pH should be maintained in the range of HOCl stability [4].

By Zoheir Khademian, Gabriel S. Esterhuizen, Morgan Sears

Based on the 2010-2019 Mine Safety and Health Administration (MSHA) accident report database, 91% of reported ground control accident in the US longwall mines were caused by gateroad roof instability. This can be related to the significant changes in loading conditions that gateroads are subject to from the development to the longwall abutment loading phases, combined with the thinly bedded shale roof, found in many US longwall coal mines. One of the challenges in designing efficient support systems is to understand the roof instability mechanisms along with support-roof interactions under this complex loading condition. Field monitoring of roof displacement and stress changes coupled with detailed analyses using numerical models are well-documented techniques to study the causes of roof instabilities. However, traditional modeling techniques require additional calibration to simulate delamination and buckling of shale roof, one of the main roof instability mechanisms in longwall mines. One alternative modeling technique is the UDEC Bonded Block Method (BBM) where bedded roof and support interactions can be explicitly captured. This paper presents the development of a BBM model of a longwall entry at a 180 m depth of cover with a three-entry gateroad layout along with roof extensometer monitoring results. The models are validated against the monitoring data, showing the potential for BBM numerical models capturing the complex roof and support system interactions to assist with optimizing gateroad layouts and support systems.

By Mark Van Dyke, Ted Klemetti, Jake Beale, Zoheir Khademian, Joe Wickline

In 2016, a 3.7-ML magnitude event caused by mining activity occurred at a longwall mine in southwestern Virginia which was recorded by the United States Geological Survey (USGS) and felt by local residents. The event was the largest of its kind since a global mine design change by the operator was instituted in 2008 following three large events in 2005, 2006 and 2007 (3.4, 4.3, and 3.4, respectively). Two of the three pre-2008 events (2005 and 2007) damaged ventilation controls in the mine which fueled a mine fire. In 2016 the mine’s management requested researchers from the National Institute for Occupational Safety and Health (NIOSH) to access geological data and determine what parameters could possibly lead to events of a magnitude of 1.0 ML or greater. Evaluation of 2,152 geological data points and modeling revealed three major geological factors in common with the majority

By D. Parks, A. Miller, M. McNinch, R. Jacksha

Each year, hundreds of mine workers are involved in machinery-related accidents. Many of these accidents involve inadequate or improper use of lockout/tagout (LOTO) procedures. To mitigate the occurrence of these accidents, new safety methods are needed to monitor access to hazardous areas around operating machinery, improve documentation/monitoring of maintenance that requires shutdown of the machinery, and prevent unexpected startup or movement during machine maintenance activities. The National Institute for Occupational Safety and Health (NIOSH) is currently researching the application of Internet of Things (IoT) technologies to provide intelligent machine monitoring as part of a comprehensive LOTO program. This paper introduces NIOSH’s two phase implementation of an IoT-based intelligent machine monitoring system. Phase one is the installation of a proof-of-concept system at a concrete batch plant, while phase two involves scaling up the system to include additional sensors, more detailed safety/performance metrics, proximity detection, and predictive failure analysis.

By I. Raposo, I. Moreno-Ventas, A. Palma, M. J. Díaz, M. Vázquez

The oxidative degradation kinetics of chalcopyrite have been studied by thermogravimetric analysis (TGA). The obtained data are necessary for the kinetic description of the flash fusion process, which can contribute to the optimization of the smelting process in copper extractive metallurgy. Activation energy (Ea) evolutions of the involved processes have been determined by several isoconversional methods; in this sense, the chalcopyrite oxidation processes could be adequately described, among studied models (E1641–16, Ozawa–Flynn–Wall, Kissinger–Akahira–Sunose and Friedman), by the Kissinger–Akahira– Sunose kinetic model. Using this method, Ea and A values are found to be very dependent on the conversion. Under lower conversion levels, higher Ea and A values have been calculated with respect to that found for medium and higher conversion levels.

By M. SIDDARAJU, Rameshwar Sah, T. Umadevi, K. S. SRIDHARA, M. RAJU, GANESH SHETTY

With the depletion of high-grade iron ore resources, the utilization of existing low-grade iron ores, fines and tailings with effective beneficiation is inevitable to meet the iron and steel industry’s required specifications and demand. JSW Steel Limited is operating a 17-mtpa beneficiation plant at its Vijayanagar site in Bellary in Karnataka, which produces nearly 50 to 54 percent concentrate as sinter-grade fines. The sinter base mix consists of iron ore fines that are smaller than 10 mm, with 41 percent smaller than 0.150 mm; washed ore that is generally smaller than 3 mm and bigger than 0.150 mm, with 3 to 9 percent smaller than 0.150 mm; beneficiation plant concentrate, with 97 percent smaller than 0.150 mm; limestone; dolomite; coke breeze; lime; sinter return fines; direct reduced iron (DRI) fines; and micropellets produced from steel plant waste. Using more washed ore in the sinter base mix affects the sinter quality. Ball formation in the mixing and nodulizing drum is an important step in sinter making and requires sufficient quantity of smaller than 0.150 mm fines. Optimization of fines in the sinter base was carried out by replacing the smaller than 10 mm iron ore fines with washed ore. Size analysis, study of the granulation index (G index) and optimization of moisture with respect to sinter bed permeability were carried out to optimize the proportion of smaller than 0.150 mm fines in the sinter base mix as adhering material. This study explores the optimization of fines in the sinter base mix for ball formation to achieve higher sinter quality and productivity with higher sinter bed permeability.

By Sandeep Kumar Jeripotula, Govinda Raj Mandela, Aruna Manglapady

Dozer operators are frequently exposed to whole-body vibration (WBV) during the execution of their work. Occupational exposure to WBV in Indian surface coal mines was evaluated by measuring vibration intensity and duration of exposure. A triaxial accelerometer was placed on the operator seat surface for taking the readings. Based on frequency-weighted root mean square acceleration equivalent to 8-hr shift duration, i.e., (A(8)) all dozer operators have exceeded an Exposure Action Value (EAV) of 0.5 m/s2 , and 90% of dozers did not exceed Exposure Limit Value (ELV) of 1.15 m/s2 . Based on Vibration Dose Value (VDV (8)), all dozer operators have exceeded Exposure Limit Value (EAV) of 9.1 m/s1.75, but no dozer operators have exceeded Exposure Limit Value (ELV) of 21 m/s1.75. Further, an epidemiological study was performed for identifying the extent of musculoskeletal disorders (MSDs) among dozer operators. For the detailed study, 42 dozer operators and 22 controls were selected from 2 surface coal mines. The control group was not exposed to WBV. It was seen from the cross-sectional study that pain in the lower back was predominantly higher (83.33%) in the exposed group when compared with the control group (31.81%). Likewise, pain in the neck (47.61%), shoulder (42.85%), knees (42.85%), and ankle (11.90%) was higher in the exposed group than that of the control group (22.71%, 0%, 45.45%, and 4.54%). A significant observation among the exposed group was that there was degradation in the quality of life. The outcome of the study would assist in monitoring and mitigation of machinery-induced vibration diseases (MIVD) in India and generally applicable to most of the mechanized mines as well. However, comprehensive studies are still needed to enunciate the magnitude extent.

By Yuting Xue, Gamal Rashed, Zoheir Khademian, Morgan Sears

Mining has been recognized among the most hazardous industries in the United States, despite the significant reduction in injury and fatality rates over the past century. This study focuses on the ground-fall incidents classified in the Mine Safety and Health Administration (MSHA) database as “fall of roof, back, or brow from in-place” and “fall of face, rib, pillar, side, or highwall.” The main objective of this study is to conduct a comprehensive statistical analysis of the reported ground-fall incidents from 2010 through 2019 including both coal and metal/non-metal mines. Since most of the ground-fall injuries and fatalities occurred in underground coal mines and were attributed to falls of roof and rib, an additional analysis was directed to evaluate roof- and rib-fall incident trends in underground coal mines associated with the mining method, coal-seam thickness, mine size, and the seasonal effects.

By Eugie Kabwe

The effective employment of a pretensioned bolt within support structures requires an appropriate installation tension as a result of sufficient bolt head/nut preload. In this paper, a load indicator washer (LIW) able to withstand an assigned static loading as well as provide an appropriate pretension is presented. The different LIW breadths are numerically analyzed with ABAQUS finite-element code to estimate deformation when a designated 60 kN preload is applied. The numerical simulation employs the bilinear isotropic hardening constitutive law governed by the von Mises yield criterion. The simulation also considers the nominal temperature of the nut-LIW-rock bolt connection. Therefore, long-term relaxation effect on bolt pretension as a result of stress relaxation is neglected. The compressive force required to achieve the LIW predetermined deformation is the bolt pretension. It is drawn from the simulation results that LIWs with thicknesses of 1.5, 2.0, 3.0, 3.5 and 4.0 mm are completely flattened when subjected to 28, 42.5, 65, 76 and 88 kN preloads, respectively.

By Roe-Hoan Yoon, Kaiwu Huang

Derjaguin and Dukhin (1961) were the first to develop a model for bubble-particle interaction in flotation from first principles by considering the surface forces in wetting (or flotation) films. The model predicted that the energy barriers to bubble-particle attachment arise from the ζ-potentials of fine particles, which corroborates well with an earlier work of Fuerstenau (1957) reported for the flotation of quartz using dodecyl ammonium acetate (DAA) as collector. In the present work, a series of surface force measurements have been conducted by accurately monitoring the changes in bubble curvature during bubble-silica surface interactions. The curvature changes are then used to determine the capillary force, which is the sum of the hydrodynamic and surface forces. By subtracting the former that can also be determined from the curvature changes, one obtains the surface forces (or disjoining pressure). The results obtained as functions of pH and collector concentrations show that control of the ζ-potentials of bubbles relative to those of the silica surfaces is critical for maximizing the negative disjoining pressure, which is conducive to promoting bubble-particle attachment in flotation.

By Thomas Novak, Sampurna Arya

Controlling dust generation and keeping it below permissible limits to meet federal dust standards at the working face of a roomand-pillar coal mine is a challenge for a mine operator. With the recent changes in federal dust regulations requiring lower worker exposure, maintaining compliance has become increasingly difficult. The current most effective practice of dust control at a continuous miner face in an underground mine is the use of a flooded-bed scrubber. A study carried out by the National Institute for Occupational Safety and Health (NIOSH) indicated that a flooded-bed scrubber could achieve cleaning efficiencies between 58 and 90%. But, the operation of such a system is maintenance intensive. The flooded-bed scrubber screen becomes clogged with dust particles and requires frequent cleaning to maintain performance. However, the dust control issue is not solely a mining industry problem. Other industries face similar issues. The University of Kentucky collaborated with Toyota Motor Manufacturing on the development of a novel wet scrubber, called the vortecone scrubber, for capturing oversprayed paint particles in automotive paint booths. The vortecone scrubber achieved a cleaning efficiency of 99% and required minimal maintenance. This study aims to assess the ability of this vortecone scrubber to capture respirable dust in an underground coal mine. The paper presents the results of computational fluid dynamics (CFD) modeling of this vortecone scrubber. It discusses the effects of air quantity and dust particle size on the performance of the scrubber.

By Eugie Kabwe

Rock bolts are components of tunnel support structures and their efficacy in reinforcement requires the appropriate estimation of the bolt pre-tension. However, cases of ineffective rock bolt application due to loosening are common which leads to the potential failure of the support structures, thus negatively affecting the tunnel stability. The effective employment of pre-tensioned bolt within support structures requires an appropriate installation tension as a result of sufficient bolt head/nut pre-load. Henceforth, this paper presents a load indicator washer (LIW) capable of withstanding assigned static loading as well as provides an appropriate pre-tension. The different LIW breadths are numerically analysed in the finite element code (ABAQUS) to estimate deformation when a designated 60-kN pre-load is applied. The numerical simulation employs a bi-linear isotropic hardening constitutive law governed by the von Mises yield criterion. The simulation also considers the nominal temperature of the nutLIW-rock bolt connection. Therefore, a long-term relaxation effect on bolt pre-tension as a result of stress relaxation is neglected. The compressive force required to achieve the LIW-predetermined deformation is the bolt pre-tension. It is drawn from the simulation results that the 1.5-, 2.0-, 3.0-, 3.5-, and 4.0-mm-thick LIWs are completely flattened when subjected to 28-, 42.5-, 65-, 76-, and 88-kN pre-load respectively.

By Richard A. Thomas, III JAMES H. ROWLAND, Liming Yuan

This paper presents the results of large-scale fire experiments on evaluating the performances of carbon monoxide (CO) and smoke sensors at low ventilation velocities. Experiments using three different combustibles — conveyor belt, coal and diesel fuel — were conducted in the experimental mine at the U.S. National Institute for Occupational Safety and Health (NIOSH) Bruceton Research Facility. A total of eight sensor stations were located downstream of the fire with each station containing sensors for CO, smoke, carbon dioxide (CO2 ), oxygen (O2 ), humidity, barometric pressure and temperature, as well as two airflow sensors. The airflow velocity ranged from 0.22 to 0.26 m/s (44 to 51 fpm) in the tests. The response times were recorded for the CO and smoke sensors at each sensor station when smoke and gaseous products of combustion from each burning combustible reached the station. The response times of the CO sensors were used to determine the appropriate sensor spacing in the belt entry with a low air velocity. The performance of the smoke sensor was found to be affected by the high humidity in the experiments. The results on proper selection of sensors and the determination of sensor spacing at a low ventilation velocity can be helpful for ensuring sufficient early fire warning for underground workers, thereby improving the health and safety of miners.

By S. Castro, L. Gutierrez

A classification of flotation processes carried out in concentrated electrolyte solutions, e.g., seawater, is proposed using the most obvious features of these processes: low or high content of Mg2+ and Ca2+ ions, pulp ionic strength, and pH. The first distinguishable group is the processes carried out in NaCl/KCl solutions, about 0.5 M in the case of salt flotation of inherently hydrophobic minerals, and at concentrations about 10 times higher in the flotation of potash ores. In the flotation of sulfide ores, such as nickel or copper ores, with xanthate-like collectors, the xanthate collector is apparently not affected by pulp ionic strength and only adjustment of frother may be required. Content of Mg2+ and Ca2+ ions in seawater is the main difference between such systems and fresh water. The presence of these metallic ions can adversely affect flotation in the pH ranges over which these ions hydrolyse. The successful flotation of Cu-Mo ores typically requires depression of pyrite at high pH values achieved with the use of lime. However, in seawater, flotation of Cu-Mo ores requires removal of the hydrolysis products of the Mg2+ and Ca2+ ions or the use of a pyrite depressant that can be effective over the pH ranges that are much below the pH of hydrolysis. Mg2+ and Ca2+ ions also affect flotation of phosphate ores with fatty acids. In this case, the depression mechanism is not caused by precipitating magnesium hydroxides on the mineral surface but by precipitation of collector insoluble salts, and the same ions are responsible for depression in both cases. In the seawater flotation of Cu-Mo sulfide ores and phosphate ores, the practical solution involves either removal of Mg2+ and Ca2+ ions prior to the flotation or complexation with other reagents.

By Xiaoyan Luo, Congcong Dai, Gaipin Cai, Xin Liu, Lu Zong

To overcome the difficulty of accurately judging the load state of a wet ball mill during the grinding process, a method of mill load identification based on the singular value entropy of the modified ensemble empirical mode decomposition (MEEMD) and a probabilistic neural network (PNN) classifier is proposed. First, the MEEMD algorithm is used to decompose the vibration signals recorded under different load states to obtain the intrinsic mode components, and a correlation coefficient threshold is used to select the sensitive mode components that characterize the state of the original signal. Second, singular value decomposition is used to obtain the singular value entropy. Finally, the load state of the wet ball mill is judged based on the magnitude of the singular value entropy. A characteristic mill load vector is constructed from the singular value entropies of the cylinder vibration signals recorded under different load conditions and is used as the input to a PNN, which then outputs the predicted ball mill load state; in this way, a load state identification model is established. Grinding experiments are presented to verify the effectiveness of the proposed method, showing that the method can accurately identify the load state of a wet ball mill. ()

By Kenneth N. Han

The effect of anions such as sulfate, chloride, and nitrate on the solubility of rare earth element-bearing phosphates and fluorocarbonates has been examined using relevant thermodynamic data. The study has found that these anions have significant influences on the overall dissolution of rare earth elements (REEs) from various sources in the aqueous media. The thermodynamic calculations in this study have indicated that the speciation of REEs with the anions tends to increase the overall solubility of the REE-bearing minerals. However, in some cases, strong precipitation of REEs with some of these anions causes an adverse effect on the solubility of these elements. It has been found that sulfate ion has the most pronounced effect on the solubility compared to nitrate and chloride, in which the latter two acids exhibited almost identical results. The calculated results have indicated that REE-oxide (hydrated) is the easiest compound to dissolve, followed by carbonate, phosphate, fluoride, sulfate, fluoro-carbonate, and oxalate in that order.