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By J. T. Clancey

The potential inadequacy of natural gas reserves to supply projected requirements in the 1980's has been pointed out.(1,2) As a result, interest has arisen in the development of new, potentially low-cost processes for the conversion of coal into high BTU gas. In June, 1964, the office of Coal Research (U. S. Department of interior) and Consolidation Coal Company (now a subsidiary of Continental Oil Company) entered into a contract to continue work on coal gasification utilizing the Consol CO2 Acceptor Process. Work under this contract has been specifically directed toward the use of lignite as the carbonaceous feed, although the process is also applicable to non-caking subbituminous coals. The primary objective of this work was to establish the technical feasibility in continuous bench-scale equipment, of the novel features of the C02 Acceptor Process. Secondary objectives were the testing of commercially obtainable acceptors and the design and economic evaluation of a commercial facility. The bench-scale process development has been completed successfully and the construction of a large pilot plant at Rapid City, South Dakota, has been authorized. It is the purpose of this paper to review the technology of this new gasification process and to present the current projected economics of a plant producing 250 MM SCFD of pipeline quality gas.

Jan 1, 1969

By Chris McKee

Quartz has been of interest in occupational health for years because it can cause silicosis after prolonged exposure. New OSHA regulations (Air Contaminant; Final Rule) list perlite as a nuisance dust. They conclude that perlite is nontoxic when air-borne total particulate concentrations are 15 mg/m3 or below and when quartz content is less than 1% crystalline silica. OSHA has established an 8-hour PEL of 15 mg/m TWA for total perlite dust containing less than 1% quartz. OSHA has established a 5 mg/m3 TWA PEL for respirable perlite. These limits will protect workers from significant risk of eye, skin, or other physical irritation. This regulation is based on a Group 2A classification as a probable carcinogen in humans, at the 0.1% crystalline silica level, by the International Agency for Research on Cancer (IARC 1987a, b). IARC found sufficient evidence for carcinogenicity of crystalline silica in animals and limited evidence in humans. Perlite is not listed as a carcinogen by OSHA or the National Toxicology Program.

Jan 1, 1990

By T. C. Canter

Technological change is continually affecting the mining industry and the many papers being presented at this meeting reflect this fact. I fully agree that miners must remain fully cognizant of technology that can change mining costs and therefore your competitive marketplace. Despite the embrace of new technology and effective mine management techniques, the mining enterprise may not realize increased net income if the structure of the minerals marketplace is not understood. An important segment of the marketing structure for minerals is transportation. Transportation costs per ton can be much greater than the mining costs per ton and may accordingly overshadow hard earned gains in productivity. Change is greatly affecting the transportation industry but the change is driven more by governmental policy than technology. Although some technological advances are occurring in the bulk transportation business, the changes I want to address arise from policy. Policy changes have come from legislation in the 1970's culminating with the Staggers Act of 1980 and ensuing Interstate Commerce Commission decisions.

Jan 1, 1985

By R. A. Jankowski

Although the number of operating longwall mining systems has remained relatively consistent over the past five years, longwall production levels have increased significantly during this period. Longwall production currently accounts for approximately 50% of U.S. underground coal production. While longwalls are highly productive and offer other advantages, operations employing this method of mining continue to experience dust compliance problems. This increased longwall productivity has meant that far more dust is being produced. An improved understanding of the longwall face ventilation system and advancement of face ventilation technologies are necessary to ensure all face personnel are allowed to work in an environment that is free of excessive levels of airborne respirable coal mine dust. The Dust and Toxic Substances Control Branch of the National Institute for Occupational Safety and Health's Pittsburgh Research Laboratory has examined several basic principles of the longwall face ventilation system, and has evaluated the effectiveness of numerous improved face ventilation techniques for longwall mining systems. These include identifying improved techniques for measuring face ventilation parameters on longwall mining sections and investigating the fundamental relationship between face air flow and the entrainment and dilution of respirable coal mine dust. Studies have been completed to determine the impact on face dust levels from using belt entry air to ventilate the longwall. Novel methods have been identified to increase the amount of face air flow and to manage face air flow to most effectively minimize face workers' dust exposure. Unique systems of auxiliary face ventilation have been developed and evaluated at full-scale, simulated longwall test facilities. The theoretical and applied aspects of each of these principles and technologies are discussed. Application of these results, throughout the longwall mining industry, as documented from surveys conducted in the early 1980's and 1990's, have reduced the health hazard associated with excessive exposure to respirable coal mine dust.

Jan 1, 1998

By Daniel M. Flanagan

"Editor’s note: Each year, Mining Engineering features an industrial minerals review. Several people put in a fair amount of time in developing the material for this issue, all the while doing their own jobs. Thank you to the industrial minerals annual review editor, to the Industrial Minerals & Aggregates Division technical committee chair and vice chairs, and to the authors of the individual commodity profiles. Jim Norman, member SME, of Tetra Tech, is the industrial minerals annual review editor.Joe Garska, member SME, of Imerys, is chair of the Industrial Minerals &Aggregates Division’s Technical Committee.The technical committee vice chairs include:• Hyunjung Kim, member SME, of Chonbuk National University, agricultural materials.• Xihui Lin, member SME, of Kemira, ceramics and refractory materials.• Nikhil Gupta, member SME, of Virginia Tech, chemical raw materials.• Adam Rodriquez, member SME, of Penn State, construction aggregates.• LeDeana Roberts, member SME, of Imerys, fillers and pigments.• Harsha Kolla, member SME, of ChemEOR, sorbents, filters and process aids.• Edgar Blanco, member SME, of FLSmidth, specialty minerals.Their help makes possible this July industrial minerals issue. On behalf of ME readers, the editors thank them.During the past 25 years, U.S. ball clay production (the quantity sold or used by domestic producers) increased from 788 kt (869,000 st) in 1990 to an alltime high of 1.31 Mt (1.44 million st) in 2003 (Fig. 1). Housing construction within the United States, a leading market for ball clay-based ceramics and sanitaryware, began to decline in 2005, which resulted in a considerable decrease in sales of ball clay that continued through the 2008-2009 economic recession. After bottoming out at 831 kt (916,000 st) in 2009, ball clay production steadily increased through 2015 (Fig. 1). Estimated sales in 2015 were 36 percent higher than those in 1990 and 18 percent lower than those in 2003.Four companies (H.C. Spinks Clay Co., Imerys S.A., Old Hickory Clay Co., and Unimin Corp.), mined ball clay in five states during 2015. An estimated 1.7 Mt (1.18 million st) of ball clay valued at an estimated $47.5 million was sold or used by U.S. producers, a 4-percent increase from 1.03 Mt (1.14 million st) valued at $45.2 million in 2014. Approximately 65 percent of total ball clay production was air-float, 25 percent was crude or shredded and 10 percent was water-slurried"

Jul 1, 2016

By E. H. Cho

An acid mine drainage sludge sample containing 3.6% Mn, 0.18% Ni, 0.15% Co and 0.39% Zn was obtained from the central part of West Virginia and leached with sulfuric acid at pH 3 and at room temperature. Air was bubbled through the leach solution to precipitate the iron content from the solution at pH 4.5. The leach solution contained 258ppm Zn, 105ppm Ni, 90ppm Co and 2050ppm Mn. Three distinctive solvent extraction studies were performed to selectively extract these metal ions in a sequential operation with DEHPA, Cyanex 272, and then Lix 84. The AIO ratio was 1 and the extractants were diluted 10 times with kerosene. A study of solvent extraction with DEHPA showed that Zn could be extracted without Ni or Co up to pH 2.75. A pH of 2.75 is considered to be the optimum pH to maximize the selective separation of Zn from Mn. The separation factor of Co over manganese suggests that the two metal ions be extracted together by Cyanex 272. The separation factor of Co over Ni indicates that these two metal ions can be separated most effectively around pH 5.3. Also, Ni can be effectively extracted by Lix 84 above pH 5.5.

Jan 1, 1993

By J. Oliver, J. Cleason

"With maintenance costs rising and an increasing demand for higher production, the use of sealed spherical roller bearings can reduce maintenance costs while providing increased production uptime. The sealed spherical bearing has increased bearing life by slowing the ingress of contamination. This paper will describe how contamination and bearing wear is reduced by reviewing case histories from coal and metal mines that improved their production by decreasing downtime using sealed spherical roller bearings. INTRODUCTION The spherical roller bearing (SRB) is a robust rolling element bearing that can accommodate high radial loads, low to moderate axial loads, and misalignment with no loss in carrying capacity. (i.e. Figure 1) Because of these characteristics, it is a favorite in mining applications and many other heavy industry applications. Primary applications are the various pulleys on conveyors. Coal and hard rock mines have hundreds of miles of conveyor lines and countless head, tail, drive, and idler pulleys. Maintaining the bearings on these pulleys and replacing bearings that have failed can be a huge expense to a mine in components, labor and downtime. Ideally, the bearings are replaced when the pulley is changed out according to the maintenance cycle, about every 4 years. Reality, however, causes the bearings to be changed out every year, or sooner. These premature bearing replacements can cause production shut downs for as long as 8 hours. Conveyor pulleys have been targeted at many mines as the single biggest maintenance pain point.The primary reason for replacing conveyor bearings is internal wear from fine, solid particle and water ingress through the bearing housing seals. (i.e. Figures 2 & 3) Traditionally, the bearing is mounted in a split pillow block housing (SAF, FSAF, SDAF or SNL are typical industry styles) with only labyrinth seals (LER/LOR) for protection against the ingress of contaminants. The bearings are lubricated with grease. A common way to extend the MTBR is to purge the bearing system with large quantities of grease to flush out the contaminants. If the bearing, and thus the housing seals are not frequently purged with grease, fine solid contaminants enter the housing and bearing through the labyrinth cavities."

Jan 1, 2015

By P. C. van Aswegen

The Bacterial Oxidation (BIOX®) process for the pre-treatment of refractory ores for gold recovery developed by Genmin, the mining division of Gencor, has been operating successfully at the Fairview mine since October 1986. The continuous operation of a pilot plant at Genmin Process Research has resulted in further process developments to improve plant operating efficiencies. These new developments which include a higher solids content of the pulp feed to BIOX®, lower retention times, higher operating temperatures, lower power utilization for oxygen dispersion .and reduced nutrient addition have all been successfully implemented on the Fairview plant.lt has furthermore been confirmed that the arsenic precipitate formed in the neutralization of effluent solutions complies to the United States of America EPA standards. Continuous cyanidation pilot plant work conducted on BIOX® product has indicated that cyanide consumption can be drastically decreased if a continuous flowsheet is implemented in preference to a batch leaching system.

Jan 1, 1991

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 R. L. Virta

Four companies ? H.C. Spinks Clay Co., Inc., Imerys, Old Hickory Clay Co., and Unimin Corp. ? mined ball clay in four states in 2013. On the basis of preliminary data, production was 1 Mt (1.1 million st) with an estimated value of $47 million. Production increased by 3 percent in tonnage from 973 kt (1.1 million st) with a value of $45.1 million in 2012. Tennessee was the leading producer accounting for 64 percent of domestic production, followed by Texas, Mississippi and Kentucky. About 67 percent of total ball clay production was airfloat, 22 percent was crude or shredded and 11 percent was water-slurried.

By D. E. Hulse

"Social License, the consent of the neighbors and community to develop and operate a mine, has received little attention until recently. Though social license is intangible, not having this relationship with the community carries operational and economic risk to a project, potentially including future impairment of the asset. Acquiring and maintaining social license is a long term personal relationship. It requires communication, commitment, consistency, and transparency. This presentation will review the building blocks to acquire and maintain a social license based on experiences with mining projects in Mexico. INTRODUCTION Mining has been a source of controversy for at least 500 years. “Since there has always been the greatest disagreement amongst men concerning metals and mining, some praising, others utterly condemning them” (Agricola 1556). In 2015 it is widely recognized that mineral resources and reserves must give due regard to the social license in order to operate. “Most commonly, the SLO is understood to refer to ‘the ongoing acceptance and approval of a [project] by local community members and other stakeholders that can affect its profitability’ (Moffat 2014).” “Social License to Operate has gained traction, in part, because it is also a concept which – while remaining poorly, technically defined – is generally easily and widely understood by community stakeholders.” (Bice 2014) A generation ago I learned that mining is based on a stable platform supported by three pillars, geology, mining and metallurgy. The three legged stool is a very stable structure.In 2015 it seems that we have added some other legs to the stool. The JORC code addresses “social, and governmental factors” (JORC 2012), and refers specifically to social license in Section 4 of the Report Template “Estimation and Reporting of Ore Reserves”. The Canadian CIM Guidelines refer to “environmental, legal and social data” (CIM 2003).Compared to these the 2014 SME Guide is positively verbose stating “a discussion of any potential social or community related requirements and plans for the project and the status of any negotiations or agreements with local communities,” (SME 2014) although in all cases the scope of this disclosure is left at the discretion of the Competent Person."

Jan 1, 2016

By E. O. Jacobs

A coupled solid and rock fracture mechanics model is used to analyze the blast driven fracture propagation phase, predict propagation rates, and directly measure shockwave and particle velocity. The study incorporates quasi-static pre-stress conditions for different depths below the surface. The scaled experiments include dynamic material properties and quasi-dynamic fracture mechanics which are shown to significantly affect the fracture propagation. The study was performed using three-dimensional cube-type laboratory models fabricated from Polymethylmethacrylate (PMMA). The test cubes are loaded with explosives and resulting fracture networks are studied. The dynamic evaluation of the spatial crack system is monitored using a high speed image camera. An experimental model set-up is designed to indicate the pre-stress effect on deep borehole blasting and is shown that the pre-stress conditions have a decisive influence on fracture profiles and orientation. It is found that shockwaves rapidly exceed the slower dynamic fractures and a majority of cracks occur due to detonation pressure. Experimental testing using different parameters validate that explosive fracturing can predict the outcome of fracture and crack propagation in any rock type with known material properties. This can be accomplished under great stress conditions deep below ground surface. The experimental study results can be applied to a variety of industries such as mining and quarrying, tunneling, oil and gas, and construction.

Feb 23, 2014

By K. Peri

The leaching behavior of gold in ammonical solutions with iodine as an oxidant has been investigated using cyclic voltammogram and Tafel polarization. The majority of experiments was carried out at 75°C and the results were compared with the equilibrium consideration on the iodine-ammonia system. The distribution of nine iodide containing species at various pH values in the absence and presence of ammonia was considered at three different temperatures. It was found that by introduction of ammonia into the system, the concentration of iodide (r), iodine (12) and triiodide (13') is increased substantially which in turn helps the rate of dissolution of gold. The apparent activation energy was found to be about 46 kJ/mole, indicating a chemical controlled mechanism.

Jan 1, 1999

By Stanley M. Moos

In reviewing available vacuum filtration equipment in this paper, several types of filters have been included which are probably not familiar to operators in the mining industry. However, it was felt that these units might be of interest in the event that an application should arise for the filtration of a product in the future that does not exist today. In addition, exposure of our industry to equipment used in other industries might have a tendency to be thought provoking and perhaps lead to the development of equipment and/or applications in our industry which do not necessarily exist at this time. Most innovations in filtration equipment have been confined to the improvement or design change of components and accessories, particularly reflecting the availability of materials of construction that have been developed. Recent developments in the application of horizontal belt filters have been innovative. The application of this unit as a substitute for or an adjunct to thickeners in a CO circuit can certainly be innovative and perhaps provide a basis for reduction in capital and operating costs in this area. For example, mill tails are generally pumped at the highest possible density that will adequately flow. Tailings ponds and dams with their attendant design requirements are based upon this estimated water volume. Availability of a much dryer, non-flowing filter cake opens up several new options for disposal. Considerable cost savings could result in the design and planning of disposal areas for containing dryer material. . No attempt has been made in this paper to provide a manual for the operation of all of the many types of equipment that are available. Rather, the paper tries to present an overview.

Jan 1, 1978

By RICKARD HANSEN

With vehicles frequently found in underground mines and tyres being a major fuel item, the risk of tyre fires will be severe underground. This study presents an in-depth analysis of tyre fires on mining vehicles to increase the knowledge of the risk, applying data from full-scale fire experiments and CFD simulations. It was found that the wheelhouse of the loader caused an increase in the flame tilt angle of approximately 10%, decreasing the flame impingement and heat flux downstream. The flame temperature of the drilling rig tyre was found to be approximately 7% higher than the loader tyre, increasing the risk of igniting adjacent fuel items. The construction of the wheelhouse/mudguard will contribute to a longer flame length by creating a fuel-rich environment. The CFD simulations predicted higher flame tilt angles for the drilling rig case for higher flow velocities, indicating the influence of a varying wheelhouse/mudguard construction and tyre geometry on the flame tilt angle. The construction of the loader resulted in a flow behaviour, where the short distance to the front mudguard/tyre and the separation of flow directly downstream of the protruding construction led to fire gases being steered past the front mudguard/tyre. In the drilling rig case, the longer distance to the front mudguard/tyre led to fire gases being directed towards the body of the vehicle after passing the area with flow separation. An increased knowledge of the tyre fire risk on mining vehicles and mitigating measures would improve the fire safety in underground mines.

Feb 10, 2022

By Victor Romero, Steve Redmond

All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME, Inc. from sources believed to be reliable. However, neither SME nor its authors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SME and its authors are supplying information but are not attempting to render engineering or other professional services. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Any statement or views presented here are those of individual authors and are not necessarily those of the SME. The mention of trade names for commercial products does not imply the approval or endorsement of SME.

Dec 1, 2011

By Donald Hulse

"Mining has been a source of controversy for at least 500 years. “Since there has always been the greatest disagreement amongst men concerning metals and mining, some praising, others utterly condemning them…” (Agricola, 1556). In 2016, it is widely recognized that mineral resources and reserves must give due regard to the social license in order to operate.“Most commonly, the social license to operate (SLO) is understood to refer to ‘the ongoing acceptance and approval of a [project] by local community members and other stakeholders that can affect its profitability’ (Moffat, 2014).” “Social License to Operate has gained traction, in part, because it is also a concept which – while remaining poorly, technically defined – is generally easily and widely understood by community stakeholders (Bice, 2014).”A generation ago we learned that mining is based on a stable platform supported by three pillars, geology, mining and metallurgy. The three-legged stool is a very stable structure (Fig. 1).In 2016, it seems that we have added some other legs to the stool (Fig 2). The Australasian Code for Reporting of Exploration Results, Mineral Resources and Ore Reserves (JORC Code) addresses “social, and governmental factors…” (JORC 2012), and refers specifically to social license in Section 4 of the Report Template “Estimation and Reporting of Ore Reserves.”The Canadian Institute of Mining, Metallurgy and Petroleum (CIM) Guidelines refer to “environmental, legal and social data…(CIM 2003).”Compared to these, the 2014 SME Guide is positively verbose stating “a discussion of any potential social or community related requirements and plans for the project and the status of any negotiations or agreements with local communities,” (SME 2014) although in all cases the scope of this disclosure is left at the discretion of the competent person.When there are more than three legs on the stool, it is imperative that all legs be constructed exactly to the design. Any one or more legs that are out of alignment will cause the stool to wobble.Engineers are trained to create designs to meet specifications. Loads can be estimated, forces calculated and cost studies completed that will lead to, not only a stable design, but the most efficient design that meets the specifications."

Jan 1, 2015

By K. Oraee

Excessive emissions of methane from the coal seams can have a serious adverse effect on both safety and productivity of longwall coal faces. Mechanization of coal faces has increased production possibilities to the extent that normal ventilation systems may not be able to ventilate coal face areas in order to lower methane content in the air to within legal limits. Production increases may therefore be prohibited for this reason, especially in gassy seams. Methane drainage from the coal seam by means of long holes and before production starts can act as a useful remedial action. In this paper a two dimensional mathematical model has been produced. The model that is based on finite elements, simulates a methane drainage system where the resultant risk is linked to the coefficient of diffusion, coal permeability, holes pattern and the duration for which the seam is subject to drainage. It is concluded that methane drainage of this type can assist in achieving production increases in many coals seems, especially where high gas content is a virtue of the seam.

Jan 1, 2010

By Werner Wenzel

Whisker growth during the reduction of iron ores The phenomenon of whisker growth can be observed in a number of solid-state crystallisation reactions, which, apparently, appear in6 the first instance as though they are two independent processes. From such reactions, one can find the whisker type of crystallisation on solid bodies. These examples show, that the whisker growth is neither due to certain crystal forms with predetermined temperature and pressureranges, nor to parameters, which, ad hoc, are necessary for the crystallisation. In all cases the whisker formation seems to depend on nucleation and the availability of crystallizing material in direct environment of such a nucleus, under given parameters of a system. One can generally state, that the research of whisker growth with the aim of establishing proper physical laws, to determine the foundamentals of whisker formation and whisker growth, is at present under active study. We can conclude that, although a great number of hypothesis have been proposed; no concluding theory has yet been arrived at. In the institute for ferrous metallurgy of the technical university of Aachen, research works are undertaken to find an explination to various metallurgical phenomena through help of whisker growth which was observed under varying conditions of iron ore reduction. This was possible by using refined microscopic techniques through which the whisker growth on solid oxyde substrates is detected. This refined technique combines the latest methods of surface examination with the help of stereo-scan-electron-microscope and proper and carefull preparation of surface to be stereo-scanned.

Jan 1, 1971

By Joseph Moses Botbol

The disposition of world mineral resources is such that a vital need exists for both the most efficient development of existing resources and the rapid disclosure of as-yet undiscovered resources. The technological developments described in this report are directed primarily toward the acceleration and increased efficiency of mineral-resource exploration program. In the past decade the use of computers in the mineral industry has grown exponentially. Most computer applications in mineral exploration are designed to be implemented either before or after data collection. Few, if any, computer applications are designed to be used during the collection of data. One major reason for the lack of development of computer applications in this area is that comunications links do not exist between computing systems and the remote areas that host mineral-deposit exploration programs.

Jan 1, 1975