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By Harry Perry

The Bureau of Mines is glad to have this opportunity to discuss its present Coal Research Program and its significance to the industry with a group which has for many years been representative of the coal producing community. We believe we have a dynamic program that will help our vast coal resources to find their proper place in the U. S, economy. The present coal research activities of the Bureau are conducted in three organizational subdivisions: Minerals Research, Mineral Resource Development, and Health and Safety. All investigations are carried out in Bureau research facilities located in different sections of the country, Since its creation by the Organic Act of 1910 and subsequent amendments, the Bureau has worked closely with the coal industry--first by providing assistance in mine safety for anthracite and bituminous coal mining, and since that time, in providing information on conservation, safety, mining, preparation, and utilization.

Jan 1, 1966

By J. Alatalo

Autogenous grinding is a process of reducing the particle size distribution of an extracted ore by using the ore itself as the grinding media. It is a process that is difficult to control and there is a lack of knowledge of the events occurring inside the mill. To find out more about how the mill behaves under different processing conditions, a full factorial test was performed with iron ore in a pilot-scale pebble mill at the LKAB R&D facility in Malmberget. To complement this work, a strain gauge detector was embedded in one of the mill?s rubber lifters, the Metso Minerals continuous charge measurement (CCM) system, and was used to get more information about the charge dynamics. The data from the experiments has been analyzed. For production purposes, an increase in the number of particles smaller than 45 µm can be regarded as a probable increase in the production rate. The analysis shows that there will be an increase in fines at 65% of critical speed, especially when the mill is 45% full. This setting will also increase the power consumption, but improves the grindability of the ore even more. The deflection of the lifters is smaller for lower critical speeds. A higher degree of filling also gives a smaller toe angle and a higher shoulder angle as expected.

Nov 1, 2011

By J. Alatalo

Autogenous grinding is a process of reducing the particle size distribution of an extracted ore by using the ore itself as the grinding media. It is a process that is difficult to control and there is a lack of knowledge of the events occurring inside the mill. To find out more about how the mill behaves under different processing conditions, a full factorial test was performed with iron ore in a pilot-scale pebble mill at the LKAB R&D facility in Malmberget. To complement this work, a strain gauge detector was embedded in one of the mill?s rubber lifters, the Metso Minerals continuous charge measurement (CCM) system, and was used to get more information about the charge dynamics. The data from the experiments has been analyzed. For production purposes, an increase in the number of particles smaller than 45 µm can be regarded as a probable increase in the production rate. The analysis shows that there will be an increase in fines at 65% of critical speed, especially when the mill is 45% full. This setting will also increase the power consumption, but improves the grindability of the ore even more. The deflection of the lifters is smaller for lower critical speeds. A higher degree of filling also gives a smaller toe angle and a higher shoulder angle as expected.

Jan 1, 2011

Teeter-bed (i.e., hindered-bed) separators are used throughout the mineral processing industry for both classification and density separation. The high capacity and sizing characteristics of these units make them ideal for feed preparation prior to coarse flotation (+0.100 mm) circuits. Teeter-bed separators are typically easy to control with two basic operating parameters including fluidization water rate and bed level. However, data show that these two parameters greatly interact with one another. Given this finding, a high-level automatic control scheme was developed and implemented on a full-scale separator. In addition, dialogue with plant operators has led to several simple changes to an already established design that improves operational and maintenance characteristics.

Jan 1, 2010

By F. G. Loper

Simulation as a mathematical technique is not new. However, recent increases in digital computer speeds and the ease of programming with languages such as Fortran have centered a good deal of attention around simulation in the last few years, Many sophistications of the method have been developed during this time. However, the ability to simulate mathematically still hinges on the ability to ignore unimportant details which would complicate the mathematics and make simulation impractical, Thus, with this attitude in mind, it becomes very easy to design a pseudo- simulator which will predict average conditions very well, but can not truly allow a detailed study of the system being simulated. Most simulations fall into this category, along with the case mentioned here. This paper is not intended to be a critical treatise of the simulator used to study a particular mining system. Instead, it will be used to illustrate the aspects of simulator development. The steps in the development of any simulator are described, along with same detail of the phosphate mine simulator itself.

Jan 1, 1966

Many investigators believe that column flotation cells offer significant advantages over standard mechanical machines for the flotation of fine particles. However, because of their unique design and operation, conventional techniques for flotation cell scale-up and design cannot be applied to columns. In an attempt to help alleviate this problems a population balance model based on first principles has been developed for fine particle flotation in a column. Two different terms have been considered in the model, i.e., transport and rate. Transport terms, incorporating fluid flow and bouyancy, are used to describe the movement of air bubbles, unattached particles and bubble-particle aggregates along the length of the column. Rate terms, which describe the bubble-particle attachment process, have been derived from first principle considerations. Because the model is based on first principles, it can be useful for the design, control, optimization and scale-up of column flotation cells.

Jan 1, 1987

By C. A. Rowland

Autogenous grinding, defined as grinding with like material, while quite an old art has recently been revitalized. Two phases of autogenous grinding, primary and secondary, have been the subject of recent papers, technical articles and discussions. The purpose of this paper is to discuss a third phase of autogenous grinding - Intermediate Autogenous Grinding - comparing it to and indicating advantages over the other two phases. Autogenous grinding can also be called ?Rock grinding?1; that is, grinding using ore or rock from the same deposit as the mill feed as grinding media contrasted with using as grinding media steel rods, steel or ironballs, natural or manufactured iron, free pebbles, or other shapes and materials foreign to the mill feed.

Jan 1, 1964

By Ron Robinson

Booster fans have been in regular use in British coal mines since the first half of this century, but a large increase in their use did not take place until after the Nationalization of coal mines in 1947. From that time the need was identified to improve standards of ventilation in general and mining engineers specializing in ventilation were appointed at all levels in the mining industry. A comprehensive approach to ventilation surveys and planning, together with the realisation of the benefits of booster fans, led to their more rapid introduction. Many coal mines in the U.K. are at moderate depth and have virgin strata temperatures of 30°C or less. The ability to control climatic conditions by increased ventilation rather than resort to cooling systems has led to the introduction of booster fans and recirculation systems in these mines. Large makes of methane and high levels of coal dust production due to increased mechanization have also required enhanced ventilation standards. This paper deals with the reasons for selecting booster fans and the specific safety considerations involved in their use. Numbers, types and sizes of booster fans in the U.K. are outlined, together with notes on installation and performance. Remote monitoring and control from the surface is dealt with, and current legislation. The evolution of controlled recirculation is also covered starting with auxiliary fan systems in 1970 and leading to very large district schemes in the late 1980s. The research at Newcastle upon Tyne University and other establishments in the climatic conditions associated with recirculation is summarised and its use in assisting existing and proposed conventional and recirculation systems is indicated.

Jan 1, 1989

By John C. Bowling

Many recent mine developments in North America are located in remote northern regions with extreme winter temperatures in the range of -20oF to -60°F. In addition, many locations are subject to very heavy snowfall. This paper discusses some of the key considerations in the planning and design of mine plant buildings, particularly concentrators, located in these regions. SUMMARY & CONCLUSIONS The subject is considered under three main headings: I. Building Out line and Structural Frame 2. Wall and Roof Materials 3. Foundations The plan outline of a mine plant building will naturally be governed by the scope and layout of the process equipment it contains. The selection of roof profile, on the other hand, will generally depend upon a number of factors extraneous to the process e.g. snow conditions. When these factors are considered for concentrators in cold locations, a flat or stepped roof will usually be more economical and suitable than a sloping roof. The materials normally used for the structural framework of concentrators are the same as used for other industrial buildings, namely steel, concrete and wood. Structural steel, however, is the most commonly used material for concentrators in

Jan 1, 1971

By R. B. Taylor

The Esmeralda mine is located about three miles west of the town of Parral, in the State of Chihuahua, Northern Mexico, and about 400 miles south of El Paso, Texas. The area is serviced by the Interamerican Highway and a branch line of the National Railways of Mexico. The Parral district is quite typical of the semidesert of Northern Mexico, lying near the western margin of the Chihuahua basin and range province known in Mexico as the ?Mesa Central? In the immediate mine area, low rounded hills and rolling plans slope toward the Parral River. Surface elevation at the mine is 5,800 feet. The Esmeralda vein outcrops strongly, but was too low grade to be of interest to the Spaniards, The first claims were staked in 1897 and limited exploration work to a depth of 550 feet was carried out prior to 1912, at which time work was suspended. The Eagle-Picher Company acquired the property in 1944 and by surface diamond drilling outlined an orebody to a depth of 800 feet, Minas de Iguala, S. A, de C.V., one of Eagle-Picher?s totally owned subsidiary companies in Mexico, then unwatered the old workings, developed the mine, installed a modern differential flotation plant and started production lage in 1948. To the present, more than two and ahalf million tons of ore have been mined and milled producing lead and zinc concentrates.

Jan 1, 1958

By B. J. Scheiner

The Bureau of Mines has developed a system for dewatering waste slurries by flocculating mineral particles with polyethylene oxide (PEO) and dewatering the resulting flocs on static and/or rotary screens. This paper discusses data obtained from dewatering, rheology, and ion-exchange experiments. A possible mechanism is postulated for the attachment of PEO to claylike particles through a water bridge with the intershell waters of the exchanged ion and the polymer.

Jan 1, 1986

By T. Foster

The continuous operation of decanters in the mining industry relies heavily on the use of synthetic flocculants. Today, as plants seek to lower production costs by increasing throughput it is necessary to obtain optimum performance from the flocculant. Factors affecting such optimization include charge and molecular weight selection, and efficiency of mixing the highly viscous polymer solution with the feed slurry. Beyond maximizing dilution of the solution, the last factor is often ignored. This paper describes a series of calculations, based on fundamental transport theories, that have been used to describe flow conditions within decanter feed wells and to help select flocculant addition points. Examples are shown for the case of hydroxamated polyacrylamide flocculants in the Bayer Process, where proper selection of the addition points can result in lower flocculant dosage and better control of the decanters.

Jan 1, 1996

By Allister McLeod

Coal is expected to play a major role in energy supply in the next 20 years. Oil is a convenient and still reasonably abundant fuel. However, its major sources of supply are regions where there is nervousness about political stability. Uranium is a more efficient fuel - but there is a continuing community apprehension regarding its use. What coal may lack in efficiency, it makes up in long term availability and competitive overall cost. Moreover, diversity of source ensures stable long-term supply. In this way, a major role for coal in the world energy scene is assured. Cyclical considerations aside, demand for coal will increase significantly and it will meet a substantial share of new energy demand, replacing oil and gas in major industrial and electric utility markets. By around the year 2000, coal's share of world energy could reach 30% and rival oil as the largest single source of energy.

Jan 1, 1982

By Edward W. Long

The Density Separator is basically a hindered settling classifier with automatic control features that provide steady, sharp classification irrespective of extreme variations in dry tons per hour of feed solids up to the design maximum throughput for the particular material being treated. The size and capacities of commercially available units and operating data comprise the scope of the paper. Applications of the unit for other than classification are proposed, i.e. washing and desliming.

Jan 1, 1982

By Donald Babbitt

In 1971, during the planning and design stages of a $300 million expansion, the Iron Ore Company of Canada Ltd. through its Engineers, Canadian Bechtel Ltd., came out with a preliminary request for two (2) 10,000 LTPH belt conveyor scale systems. These Systems were to provide weighing accuracies within 2.5% of the iron ore pellets and concentrates in transit on two (2) 72" wide conveyors from the stockpiles to the ships. Each conveyor system would be fed by a rail mounted bucket wheel reclaimer, with the conveyed material moving directly to the ship loaders with no inter- mediate surge and/or storage bins between the stockpiles and the ships. The bucket wheel reclaimer discharge rates would vary from 0-9600 LTPH in cyclic periods, with the periods varying from 1-5 minutes - dependent on the level of the reclaim buckets in relation to the stockpile as well as the slewing rate of the reclaimer. There would be frequent interruptions for bucket wheel repositioning (laterally and vertically), changing ship holds, and trimming ship holds. These frequent zero flow conditions, approximately 500 per 150,000 ton ship, could last 1-5 minutes. In addition, the conveyors on which the scales were to be mounted would be over the water and subject to the wind and cold of Northern Quebec. These Systems would be in use 350 working days of the year and would load 30,000,000 LT/yr. (An average of 90,000/working day).

Jan 1, 1975

By P. C. Thakur

Horizontal drilling in coal mines is a relatively new technology. The earliest recorded drilling in the United States was done in 1952 at the Humphrey Mine of Consolidation Coal Company for degasification of coal seams. Spindler and Poundstone experimented with vertical and horizontal holes for eight years. They concluded in 1960 that horizontal drilling in advance of underground mining appeared to offer the most promising prospect (for degasification) but effective and extensive application would be dependent upon the ability to drill long holes, possibly 300-to 600 m, with reasonably precise directional control and within practical cost limits.(1) Mining Research Division of Continental Oil Company, the parent company of Consolidation Coal Company, began a research program in the early 1970's to achieve the above objective. The technology needed to drill nearly 300 m in advance of working faces was developed by 1975 and experiments on advance degasification with such deep holes began in 1976. Preliminary Its of this research have already been published.(2) To date nearly 4500 m of horizontal holes have been drilled for advance degasification and earlier results were reconfirmed. In summary, these are: 1) The greatest impact of these boreholes was felt in the face area where methane concentrations were reduced to nearly 0.3 percent in course of two to three months from original values of nearly 0.95 percent.

Jan 1, 1979

By Y. S. Roditis

Traditionally, open pit optimization has been used to produce a single outline which can guide the pit design. This paper describes how a series of optimum nested pits are utilized to: a. produce different mining sequences and to help in mine planning and phase design; b. evaluate different metallurgical processes, production scenarios and equipment size; c. investigate the sensitivity of a project to prices, recoveries, production rates, costs, ultimate pit slopes etc.

Jan 1, 1993

By George L. Atwood

The western phosphate field, one of the United States' great mineral resources, lies within the western states of Idaho, Utah, Wyoming and Montana. This Permian sedimentary deposit has been known since the turn of the century and since the 1920's has been mined for its phosphate content. Isolation from markets and relatively high mining costs have restricted development as compared to eastern United States deposits, but nevertheless a significant western phosphate industry has developed. Geographically the deposit covers an enormous area of about 337 000 km2 (130 000 sq miles). It covers Idaho from Pocatello east- ward, western Wyoming to the eastern flank of the Wind River mountains, and extends well into southwestern Montana and into a large area of northeastern Utah north of the Uinta Basin and east of the Salt Lake valley.

Jan 1, 1983

By Leslie G. McMillion

A field project to develop and demonstrate a method for alleviating problems of highly-mineralized ground water where they occur as isolated zones or pockets in fresh-water aquifers is being conducted in the Ogallala Aquifer of eastern New Mexico by the Robert S. Kerr Water Research Center. Removal of contaminated water is by a large-capacity well and the pumped poor-quality water is used locally for secondary recovery of oil, Benefits of the operation are threefold in that the aquifer is being reclaimed for future fresh water production, contaminated water is being used beneficially, and fresh water which otherwise would have been used for waterflooding is available for other purposes. Ground-water quality in the site has improved markedly after 21 months of operation. Water quality in 15 specially-drilled monitoring wells has returned to the original quality level of the aquifer, and chloride concen¬trations in the pumping well have dropped to half the maximum level recorded thus far. Project results are very favorable and provide guidelines for initiation of similar undertakings in localities where needed.

Jan 1, 1970

By H. Askari-Nasab, B. Osei, K. Awuah-Offei

The U.S. coal mining industry consumes approximately 142 billion kWh/a of energy. The U.S. Department of Energy estimates that the industry’s annual energy consumption could be reduced by 49%. This constitutes nearly $3.7 billion of potential savings on coal production costs at 5.3¢/kWh of energy. Additionally, with climate change regulation on the horizon, any benefits from energy savings in the near future are compounded by associated reductions in CO2 emissions. Research indicates that operating conditions significantly affect energy efficiency. Modeling and simulation have been shown to be a cheap and reliable means of evaluating the effects of process interactions and operating conditions. The goal of this work was to apply stochastic process simulation to model the energy efficiency of a typical truck-and-shovel mining system and use the model to evaluate production strategies to improve energy efficiency. The research team conducted energy audits of truck-and-shovel overburden removal and used the results to develop regression models describing truck and shovel fuel consumption. The team then built a stochastic simulation model of the truck-and-shovel overburden removal operation and used it to assess a variety of improvement measures by simulation experimentation. Valid fuel consumption models for shovel loading and truck haulage have been formulated, based on the energy audit results. Valid stochastic process models of truck-and-shovel operations have been formulated to study energy efficiency. The following strategies, in decreasing order of impact, provide the most energy savings for truck-and-shovel overburden removal at the mine: (1) shorten haul roads, (2) increase shovel capacity and (3) increase shovel utilization through optimal truck matching. Additional data will be required to adequately describe operator effects on energy efficiency.

Jan 1, 2011