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By Kenneth K. Humphreys

INTRODUCTION At the time the 4th edition of this book was published in 1979, the coal industry had experienced a sharp upturn in prices for its product. From 1950 throgh 1969, steam coal prices had held almost flat at about $5 US per st (about $5.50/t). Thus, when considering the effects of inflation, the price of coal had actually been declining for two decades. The passage of the Coal Mine Health and Safety Act in 1969 and its cost effects started an upward trend in coal prices which was rapidly accelerated by the effects of the Mid-East oil embargo in 1972. Prices of steam coal on the spot market eventually climbed to over $30 US per st ($33/t) and higher in some cases. Metallurgical coal prices skyrocketed in a similar manner and the industry at long last appeared assured of an adequate return on investment. Many companies did expend large sums of money to upgrade and expand their mining and preparation facilities. Unfortunately the bubble eventually burst, in great measure due to the downturn in the US domestic steel industry and the resultant decline in metallurgical coal demand, loss of export markets to other nations and even imports of large amounts of foreign coal to the United States, and more stringent environmental regulations which made many high sulfur coal measures uneconomical to mine. Compounding the problem was the rapid world decline in oil prices in the mid-1980s which encouraged many consumers to utilize oil rather than coal. During the 1980s, metallurgical coal dropped over 20% in price, which, when considering inflation, actually amounted to about a 40% decrease in value. Export coal decreased a similar amount in price. Steam coal prices held nearly constant, thus also losing considerable value when inflation is considered. All of these factors make it even more imperative than ever that the industry do everything in its power to make wise economic decisions and to examine carefully all existing operations and planned future expenditures to be certain that their full cost implications are understood and that they can be justified on the basis of an adequate return on investment. It cannot be assumed that the price of coal will increase. To the contrary, as indicated previously, when considering inflation, coal decreased in value in the 1980s, just as it also did in the 1950s and 1960s. The price surges in the 1970s merely were a catchup game, and in truth the true market value of coal is in reality even lower than it was in 1950. CAPITAL AND OPERATING COST ESTIMATION Prior to constructing a new plant or expanding existing facilities, a detailed preliminary cost estimate is necessary to determine the capital investment

Jan 1, 1991

By Amy McBrayer, Vladislav Kecojevic, Juan David Valencia Quiceno, Dragan Bogunovic

The mining industry’s commitment to innovation reflects a history of adopting technological advancements to enhance workplace safety, environmental sustainability and vocational training. The objective of this research was to develop an augmented- reality (AR) system for heavy-equipment operators (HEOs) in surface mining. The developed system has the potential to enhance mine safety, training and data-driven decision- making, which presents a significant step toward a more sustainable, effective and technologically driven mining training, contributing to the industry’s evolution and growth. The AR training system leverages Microsoft’s Power Platform and HoloLens 2 capacities to provide operators with detailed and immersive training guides for three mining equipment, including bulldozers, motor graders and haul trucks. AR guides combine speech controls, 3D objects, informative images and explicative videos in the real working conditions to enhance the operator’s learning process. The system has the potential to modify the training structure based on user performance and provides an efficient approach to data collection during training. This project was developed and applied through a case study in a surface mine in the Southern United States.

Feb 1, 2025

By Robert A. Jankowski, George E. Niewiadomski

INTRODUCTION The utilization of longwall mining technology in the United States has steadily increased since the first longwall plow system was installed in 1952. At the errs of FY 1992, some 76 coal mines were employing longwall mining systems for coal extraction, and approximately 78 shearer and 3 plow faces are operating nationwide at any given time. Although the number of operating longwalls has remained relatively constant over the last five years, longwall production levels have increased significantly during this period. During the same timeframe, the number of continuous miner sections has decreased by 13 pct., from approximately 1438 in FY 1988 to less than 1250 in FY 1992. According to Mine Safety and Health Administration (MSHA) data, the average production of longwall sections increased from approximately 2400 tons per shift (tps) in FY 1988 to more than 3100 tps FY 1992. In fact, the average production has more than tripled since 1978, when it was only 850 tps. Approximately 25 pct. of operating longwalls are capable of producing in excess of 4000 tps. Longwall production currently accounts for nearly 36 percent of U.S. underground coal production, compared to 4 pct. in 1978. These improvements are attributed to improved longwall equipment and increased availability, larger longwall panels and automation. While longwalls are highly productive and offer other advantages, operations employing this method of mining continue to experience dust compliance problems more frequently than other mining system. Although dust levels have remained relatively unchanged over the past five years, averaging 1.6 mg/m3 and 1.9 mg/m3 based on results of operator and inspector sampling, respectively, during FY 1992, approximately 25 pct. of the operating longwalls were in noncompliance during any given bimonthly sampling cycle. Although modest gains in longwall dust control technology have been made, these have been overshadowed by significant increases in production rates. As more coal is mined, more dust is generated (Figure 1). Therefore, the increase in longwall productivity has meant that far more dust is being produced which must be controlled. [ ] In view of the current compliance record, any efforts to further increase longwall output, as has been forecasted, must be accompanied by: (1) the reduction of dust levels at existing operations through the proper installation and maintenance of suitable engineering dust controls; and (2) the advancement of dust control technology for today's and future longwalls that will enable all face personnel o work in an environment that is free of excessive levels of respirable coal mine dust. MSHA'S RESPIRABLE DUST CONTROL PROGRAM Since 1972, federal regulations have required each coal mine operator to continuously maintain the average concentration of respirable dust in the mine atmosphere during each shift in the active workings at or below 2.0 mg/m3 through the application of environmental dust control methods. The regulations provide for further reduction in the dust standard whenever the

Jan 1, 1993

By J. Herman

The Mid-Continent Geophysical Anomaly (M.G.A.) which extends from Michigan into Wisconsin, Minnesota, Iowa, Nebraska, and Kansas, has recently been the object of intense preliminary oil and gas exploration activity involving widespread land leasing, seismic data collection, permitting of deep exploratory holes and other activities (Paul et al., 1985). This report describes the remote-sensing techniques and results of the application of these techniques to study the geology of the M.G.A. and the surroundings in Iowa. In early 1981, Coal Valley Natural Resources contracted Geospectra Corporation to find a large, (100,000 acres or larger) lease block for wildcat oil and gas exploration. The southwest Iowa area was chosen for several reasons. First, southwest Iowa contains the northeast portion of the Forest City basin (Figure 1) which has produced oil and gas from numerous fields in Kansas, Missouri, and Nebraska (Landes, 1970; Petzet, 1982).

Jan 1, 1986

By Wade W. Bristol

The Jerritt Canyon Joint Venture project is located about 80 km (50 miles) north of Elko, NV. It produces approximately 9.3 t/a (300,000 oz/year) of gold. The joint venture is 70% owned by Independence Mining and 30% by Meridian Gold. Independence Mining is the operator. The Jerritt Canyon Joint Venture started operations in 1980 by mining a series of open-pit mines. The discovery of deeper ores during early 1990s made it neccessary for the operation to mine a large portion of its annual production by underground mining methods. Underground production started in 1993 at the West Generator Mine. This was followed by the Murray Mine in late 1994. Two additional underground projects are being developed. Underground mining at Jerritt Canyon is scheduled to produce about 3.9 t (128,000 oz) in 1997.

Jan 1, 1997

By Mary Nelima Ondiaka, Oladunni Oyelola Alabi, Fatai Olufemi Aramide, Francis Gitau, Talabi Henry Kayode

Iron ore is essential in steelmaking but high-grade ores have diminished, making it necessary to turn to low-grade ores, which need further beneficiation to upgrade the iron content. Biobeneficiation techniques such as bioleaching, bioflotation and bioflocculation have proven successful in iron ore processing. Consequently, these methods have emerged as sustainable alternatives to conventional beneficiation. The biobeneficiation processes occur in mild conditions using bioreagents and biosurfactants derived from microbes, and offer a reduction of chemicals used in processing. This potentially offers methods that are relatively energy efficient, cost effective and environmentally friendly while tackling the constraints of dwindling high-grade iron ore resources.

Sep 1, 2024

By C. Douglas Lee

This case study describes the work done at the University of Arizona on the development of a computer mine model for an irregularly shaped and spotty ore deposit. The purpose of the work was to develop techniques for modeling any highly irregular deposit, for which the regular 3D fixed block model is not well suited. The deposit contained complex geology consisting of sedimentary beds that had been faulted, thrusted, and intruded by igneous rocks (see Fig. 1). The physical dimensions of the modeled ore body were 1067 m (3500 ft) along the N-S direction and 914 m (3000 ft) along the E-W direction. Topographic relief in the modeled area was approximately 274 m (900 ft). The highest grade of ore was found near the surface with mineralization extending down to approximately 152 m (500 ft) below. Using a fixed bench height of 12 m (40 ft), the model required 25 levels with the highest elevation being at 1286 m (4220 ft). Fig. 2 shows a cross section of the developed computer model of the ore deposit. The particular modeling approach selected for this deposit was the 3D irregular block model.* This meant that only the dimension of bench height was fixed at 12 m (40 ft). Irregular size blocks in the form of polygons were adopted in the model to describe the ore zones and geologic contacts. The following sections of this chapter describe some of the techniques used in modeling.

Jan 1, 1979

By A. J. Kroha, N. Wesis

Most copper mines produce both ore and low-grade "leach" rock or acid waters that contain recoverable copper. The sulfide ores pre¬dominate, and a portion that is too low grade for milling to produce concentrates for smelting, but has to be mined and trucked away anyhow, may be leached successfully with acid in dumps. Most of this leach material consists of sulfides and silicates or carbonates, and if the gangue is such that it consumes a high quantity of acid, this factor may rule out a leach operation. There are also valuable deposits that contain mostly acid-soluble copper, or occasional sulfide ores from which a sulfide concentrate can be roasted and acid-leached to produce a copper-bearing solution. Finally, there are milling ores in which the lesser part of the copper is acid-soluble and can be precipitated with iron or synthetic inorganic precipitants that produce metallic copper or copper sulfides that will float with the sulfides. Ordinarily, ores that contain copper associated with the sulfur ion, such as in the minerals chalcopyrite, chalcocite, bornite (and others), are milled to produce a 25-30% Cu concentrate for smelting, while a lesser amount of acid-soluble copper may be converted from solution to cement copper on iron scrap. A fast-growing percentage of such copper, however, is removed from solution with exchange resins or organic compounds in organic carriers such as kerosene (solvent extraction), then eluted with strong acid and subjected to electrolytic precipitation either in marketable form or as anodes that can be refined further. From the point of view of conventional copper smelting, copper flotation concentrates and cement copper are of chief interest in this chapter. Table I is a condensed open schedule for concentrates that generally run between 25 and 35% copper, and much less frequently as low as 12-15% or as high as 65-75% copper, the former being due to intimate relationship with pyrite (like the former United Verde Extension), and the latter representing such ores as the Bolivian Coro¬coro ore in which the copper is in the form of chalcocite in sandstone. These extremes are no longer common. When they occur, a special purchase schedule has to be negotiated. Included in Table 1, copper precipitates (cement copper) generally run from 70-85%a copper, and the same basic purchase schedule is used as with flotation concentrates. Sulfide Flotation Concentrates The sulfide copper concentrate produced in the mill as a flotation froth, with water then added for transportation of the heavy mineral particles from the flotation cells to thickeners, may run 60-80% water by weight, and the removal of water down to 25-50% by weight by means of thickeners, followed by further dewatering by continuous vacuum filters to 7-18% moisture by weight (depending on size of solids by screen analysis and also by content of clay) is a critical operation. Mill operators would like to produce a filter cake with 7-9% moisture content, but even with the help of steam on the filter this desirable condition is seldom realized when the concentrate is as fine as 80% -325 mesh. More commonly, the final concentrate is reground in pro- to produce best copper recovery and grade of concentrate (or molybdenite separation). In those cases, increasingly frequent, the filter product may not be a cake at all, but a mud that is hard to handle-even requiring a thermal dryer. Greater difficulty of form¬ing a manageable cake often comes from the copper-molybdenum separation by flotation, because the alkaline sulfides and hydrosulfides, or cyanide, or other similar reagents used for the separation, may leave the now relatively molybdenite-free copper concentrate even more difficult to filter. Handling a wet filter cake is difficult enough when its destination is only a short distance away-a matter of yards rather than miles. In those cases the filter cake may be thermally dried near the point of production, using rotary or multiple hearth, or fluidized-bed dryers. Alternatively, the concentrate may be pumped or carried in slurry form to the smelter and filtered there, or it may be spray-dried and compacted. For transportation to a smelter just a few miles to a few thousand miles away by ship or railroad other factors may be important, such as: in shipping by sea, avoidance of spontaneous combustion; in shipping by rail, losses by leakage if too wet or by wind and sun if too dry. It is the responsibility of the millman-usually the mill superinten¬dent-to make sure that his concentrates are in satisfactory condition when they leave the mill so that they meet these requirements: 1) They must have been accurately sampled and dry-weighed, the latter meaning that a moisture determination and gross weight must have been taken. 2) They must be dried sufficiently when necessary to prepare them for safe transportation. 3) They must arrive at the smelter with reasonable likelihood that they can be check-weighed and sampled fairly and equitably,

Jan 1, 1985

By Dermot M. Ross-Brown

The more important factors controlling the design of pit slopes are related to the local geology over which the designer has little or no control. Nevertheless, there are some factors over which the designer does exert some control and these concern the say in which the rock is excavated and supported. They include blasting, face cleaning, water control, and the use of rock improvement techniques. The paper discusses these factors and relates the extra costs incurred to the steeper slope angles that can usually be obtained. It is demonstrated that even a modest increase in bench angle of 5° through improved excavation techniques can pay off in a single push-back.

Jan 1, 1975

By R. D. Herron

Mining coal under deep cover conditions is certainly the proper phrase to use in describing one of our newest operations. Located in the southwest corner of Virginia is this operation which is the Beatrice Mine of the Beatrice Pocahontas Company, a joint venture of Republic Steel Corporation and Island Creek Coal Company. The mine is working in the No. 3 Pocahontas seam in an assigned area of over 9500 acres containing over 60 million tons of recoverable, high quality, low volatile coal. The site of the mine opening was at Keen Mountain, Virginia, where the seam lay 1350 feet below the surface. This depth, greater than anything attempted thus far in the coal industry on this continent, would pose some problems, we felt, with which we had not previously had to contend.

Jan 1, 1968

By Hector M. Valenzuela, Juan H. Rojas

This paper presents a strategic plan for automation, plant integration and process management being implemented at the Chuquicamata mining and metallurgical complex of Codelco-Chile. This five-year plan considers different levels of process control and plant integration, which include instrumentation and direct control, process models and supervisory control, plant information integration, and real time process and plant wide management. The conceptual solution developed defines an architecture for the overall system and the projects to be implemented by each production unit, as part of the proposed solution for the division wide process control, plant integration and real time process management. An estimate of the cost benefit relation of the plan is also given.

Jan 1, 1998

By James P. Dorian

istorical records suggest that the gathering of geologic information in China began more than 2,000 years ago. Modern-day geological work in the nation started in the early part of this century but it progressed rather slowly. Before the founding of the People's Republic of China (PRC), there were only 800 people engaged in geological work and only 200 trained geologists among them. According to Minerals and Mining in China, many accomplishments were achieved within China's mining industry during the period of years between 1949, the founding of modern China, and 1997. These include: ? The number of types of minerals with verified reserves increased from 18 (pre-Liberation) to 162 (today). ? Mineral deposit localities grew from 5,123 (pre-Liberation) to nearly 200,000 (today). Of these 200,000 localities, more than three-quarters have verified mineral reserves. ? Minerals extraction and processing contribute to 31 % of the total industrial output value of China (today). ? Regional geological maps at a scale of 1:1,000,000 covering the entire country have been completed, while regional geological and hydrogeological maps at a scale of 1:200,000 covering two-thirds of the country have also been finished (today). ? Before 1949, China was regarded as an oil-poor country. Since the 1950s, China has developed an extensive petrochemical industry. It is largely government-owned except for a limited number of joint ventures. The central government maintains active control over China's most productive fields, including the Daqing field in the Songliao Basin of northeastern China and the Shengli and Liaohe fields in the Bohai Basin of northeastern China. ? Employment in the minerals industry engaged in geological exploration increased from 800 (pre-Liberation) to 1 million (early this decade). The new report provides an overview of the current political and economic situation in China and discusses how this affects the minerals industry. China is in transition between a socialist planned economy and a market economy. This makes it difficult for non-Chinese to keep track of developments. Minerals and Mining in China is divided into 14 chapters that contain detailed statistics, including data on the geographical location and extent of known mineral reserves, production rates, local technical personnel, imports and exports. The report reveals which companies are already active in the area by profiling 50 major investment projects in China's metals and minerals industry. According to its author, China possesses one of the world's largest mining industries, ranking among the leading producers of several metallic and nonmetallic resources. The Chinese mining industry is extraordinarily complex. It has evolved into an overwhelmingly large bureaucracy that was, until the 1980s, shrouded from and misunderstood by the international community. To date, more than 160 types of minerals have been discovered in China. But a significant portion of the minerals and energy base remains largely unidentified and evaluated. And despite China's large reserves of mineral resources, with a population of more than 1.2 billion people, the country ranks among the lowest in the world in terms of proven reserves per capita. In addition, mining recovery rates in China average about 50%, significantly

Jan 1, 1999

By Charles A. Ramsey, Kathleen S. Smith, Philip L. Hageman

We developed a statistically based strategy for sampling the surficial material of mine-waste dumps for use in screening and prioritizing historic dumps on abandoned mine lands. This sampling strategy entails the collection of a representative composite sample from individual dumps and allows for regional or watershed-based assessments. One 30-inment dump-composite sample collected using this sampling strategy contains as much information, relative to average value, as 30 individual grab samples at 1/30 of the analytical cost.

Jan 1, 2000

By J. R. Woolsey, B. G. Noakes

A prototype remote placer drill (RPD) has been designed and successfully tested in the offshore gold district of Nome, AK. The RPD system is unique in its design and in the cooperative support that was provided during its development by industry, academia and government. The RPD was conceived as a low-cost, rapid drill sampling system for the reconnaissance of marine precious metal placer deposits. The drill functions as a counter- f lush system. It incorporates a dual wall casing and a rotating percussion bit driven by way of a drill rod through the central eductor casing by a heavy duty pneumatic rock drill. The cost of drill sampling in the exploration of marine precious metal placers has traditionally been high due to the technical difficulties imposed by the environment and the remoteness of the sampling target. The objective was to reduce capital and operating costs of a drilling program through the development of a portable system incorporating drill compoments having a high power-weight ratio that could be deployed from work vessels of opportunity. A principal design requirement was to operate the system remotely from the sea floor with only flexible connections to the surface. This includes cable for deployment and retrieval and hoses for air supply and sample recovery, thus making the drill system semi-independent of the vessel's sea-induced motion. The prototype RPD underwent full operational test off Nome, AK in late summer 1988. It was deployed from the landing door of a modified LCT vessel, and rigged for a single pass of 5 m (16.5 ft). More than 50 holes were drilled in a wide variety of bottom materials typical of the off shore Nome submerged beach placers. The prototype RPD proved to be an overall success, recovering representative samples throughout the section in all but the heavy boulder ground. Compared with a conventional drill system on board that was assigned to a production drilling system, the RPD was capable of reliably sampling moderate ground less than 6 m (20 ft) in thickness, using a smaller crew and operating in higher sea conditions.

Jan 1, 1991

By Gus Van Weert

Capital and operating costs for a 10 tpd NITROX PROCESS® demonstration plant are being established. The flowsheet is based on Dickenson Mines' Red Lake arsenopyrite concentrate. Support for the work comes from a number of mining companies, engineering firms and the Northern Development fund of the Ontario Government.

Jan 1, 1998

By R. W. Barbaro, J. M. Mutrnansky

This paper presents a nonlinear integer goal programming model that optimizes a mineral production schedule while considering the penalties and bonuses based on quality variations in the final product. It involves five coal quality goals plus a profit objective in its formulation and uses the weighting method of goal programming for a solution. The goals to be sought involve the sulfur, ash, heat content, moisture content, and ash softening temperature of the blended coal product. The model is linear in its handling of most of these goals but uses a piecewise linear integer formulation for the sulfur and heat content bonus and penalty schedule. The model is applicable to any mineral product blended from several different sources and subject to a varying price dependent on blended product quality or qualities. However, it seems to be most pertinent to optimizing production schedules for coal deliveries to power plants. Accordingly, the model is applied to a hypothetical coal production problem where multiple coal mines are operated to supply a final blended product to a power plant. In this example, the price paid for the coal is assumed to be a function of five of the most important coal qualities. The problem is solved as a direct function of the coal supply contract, thus removing the necessity of determining the weighting coefficients on a subjective basis.

Jan 1, 1987

By William A. Rhoades

INTRODUCTION Ever since miners were faced with the task of moving ore, some form of scraper has been in use. At first, men and beasts of burden supplied the power to move the scraper, and later, machines were developed for this purpose. In the early 1900s, a few mining properties used small pneumatic single-drum winches to pull loaded scrapers to a raise or ore pocket, and the empty scraper then was dragged back to the muck pile by a miner, as shown in Fig. 1. Just prior to 1920, an improvement was introduced, using two single-drum hoists. As illustrated by Fig. 2, the second hoist was used to return the empty scraper to the muck pile. However, this arrangement still re¬quired two men, one operating each hoist. The next developmental step was to eliminate the second man by locating the hoists side-by-side and using one man to control both hoists. As illustrated by Fig. 3, this involved the use of a tail rope over a sheave to pull the scraper back. The greatest progress in development and the great¬est increase in the use of slusher haulers occurred between 1920 and 1930. In 1921, the Sullivan Machinery Co. designed and built the first two-drum scraper oper¬ating on the principle illustrated by Fig. 4. It was powered by a 4.5-kW (6-hp) Turbinair(r) motor and would pull a 450-kg (1000-1b) load at 0.61 m/s (120 fpm). In 1922, this unit was shipped to the Verona Mining Co. of Caspian, MI, and it experienced immediate success in the Lake Superior iron ore district. Since the two-drum slusher was much less expensive and more efficient than hand mucking, the Lake Superior mines were saved from financial disaster when iron-ore prices fell 25% between 1923 and 1925. Immediately there¬after, a demand developed for slushers that would oper¬ate with electric power, which was considerably cheaper than compressed-air power. In 1923, the Sullivan Machinery Co. responded with the first electric-powered double-drum hoist. During subsequent years, design improvements in¬cluded separate tail-drum gearing to increase the tail¬drum speed, as welt as a number of safety features such as rope guides. One result of these improvements and their utilization by the Michigan iron mines was an in¬crease of 100% in the tons of ore per miner per day in those mines between 1924 and 1929. Since the two-drum slusher was capable only of straight-line mucking, it was not a practical machine for use in open stopes. In 1929, the Sullivan Machinery Co. introduced the first three-drum slusher. As illustrated by Fig. 5, two tail drums and one hauling drum were provided. A tail sheave could be placed at each side of the stope, and the ore then could be loaded and hauled to a central point from the entire width of the stope. During the 1930s, progressively larger slushers were demanded. By 1940, two- and three-drum units were available with motor power as high as 45 kW (60 hp), and slusher power continued to increase after 1940. Be¬tween 1951 and 1952, Joy Manufacturing Co. designed a 112-kW (150-hp) two-drum Blusher for the Climax Molydenum Co. Although there has been no demand for a slusher more powerful than this, 150- to 225-kW (200- to 300-hp) slushers are quite feasible at the pres¬ent time. During the last 30 years, many slusher improvements have been made to the operating life, operational safety, and ease of operation and maintenance. Increased tail-drum speeds have decreased overall scraping times. Rope guards, totally enclosed drums, and operator shields have reduced the hazards of injury due to wire¬rope breakage. Improvements in lubrication have made the slushers relatively maintenance-free, with long operating lives. The introduction of spring-actuated drag brakes prevented uncontrolled unreeling of dis¬engaged drums, allowing the development of practical remote-control slusher operation. Remote control now is available in a choice of all-air, all-electric, or air¬electric slushers. APPLICATIONS Quite simply, slushers are used to load and transport material (ore), generally over a short distance of from

Jan 1, 1982

By A. K. Mukhopadhyay, B. Sikdar, V. P. Arora

Introduction During the past several years, persistent concerns about an economic slowdown in India have tempered capital-expan¬sion plans. This has encouraged companies to find methods of increasing the capacity of existing production equipment. One of the more cost-effective methods of increasing produc¬tion capacity without major capital investment is to improve equipment maintenance to prevent needless machine down¬time. This can have a significant financial impact because of reduced maintenance costs and increased machine availabil¬ity. The maintenance program employs different techniques, but the analysis of the vibration behavior of machine compo¬nents to assess their condition was found to be the most accurate technique for monitoring various machine disorders. A dragline that handles overburden in open pit mines is one of the more capital-intensive pieces of production equip¬ment. It is imperative that the machine be run at its optimum capacity under the prevailing environmental conditions. Condition monitoring of the various components of the dragline through vibration analysis not only improves the machines availability but also ensures a long operation time free from sudden failure. This paper describes the application of vibration monitor¬ing and analysis techniques to assess the components of a W2000 dragline. The paper reveals that condition monitoring through vibration analysis can be as valuable in failure prevention as it is in failure analysis. Finally, the paper presents an approach to a knowledge-based expert system to the quick and correct diagnosis of mechanical faults in a dragline. Equipment A dragline is an intermittent-discharge-type excavator having a long boom at one end. Unlike other excavators, the bucket is not rigidly held by the frame structure. In favorable geomining conditions, the intensive operation of these exca¬vators is the least-expensive means of overburden removal. The basic working elements of this equipment are the hoist system, the crowd and retract system, the wing mechanism and the propel mechanism. The walking dragline is accepted as the most economical machine for stripping overburden at depths of up to 60 m (200 ft). They are electrically powered and the various motions are effected by individual drives. The Ward-Leonard system is used to provide the optimum flexibility in controlling different dc-drive motors. To mini¬mize the cost of mineral extraction, the largest such machine in India has a 24-m3 (850-cu ft) bucket with a boom length of 96 m (315 ft). Draglines are very costly, and considerable financial penal¬ties may arise from sudden stoppages due to component fail¬ures. Thus, operational reliability is of the greatest importance. Active measures are now being taken to minimize downtime by adopting condition-based maintenance techniques. Though a number of techniques come under this scheme, it has been observed that assessing the health of the dragline by measuring vibration is the best method of determining the dynamic behavior of its various rotating components to avoid any catastrophic failure. Based on criticality, the vibration-behav¬ior of the following components are studied: • motor-generator unit, • exciter unit, • hoist motor-gearbox unit, • hoist drum-gearbox unit, • drag motor-gearbox unit, • drag drum-gearbox unit and • swing motor unit The approach Increases in the vibration levels in different subsystems of the dragline were observed due to the presence of faults such as unbalance, misalignment, looseness and bad bearings. A vibration behavior study included the measurement of vibra¬tion level, trend analysis of time-domain vibration signals and vibration frequency analysis at bearing points of the components. A vibration meter, a vibration analyzer and a data collector are used. Vibration-level measurement. When the dragline was assembled and put into operation for the first time, vibration data were collected to generate baseline data for the equip¬ment (based on International Standard ISO 2372). After¬wards, the vibration levels were recorded regularly using a vibration meter. The measurements were taken at all bearing

Jan 1, 2000

By A. L. Miller, A. J. Chambers, P. R. Griffiths, D. A. Parks

"Diesel engines are one of the primary contributors to the presence of nano and ultrafine aerosols in ambient air and occupational environments. Exposure to diesel emissions has been shown to contribute to various adverse health outcomes of the pulmonary system and cardiovascular system. Currently diesel emissions in the workplace are monitored by way of collecting the aerosol onto filters, which are then sent to a lab for thermal-optical analysis using the NIOSH 5040 method, which measures elemental and organic carbon explicitly. This process can take days or even weeks, and workers can potentially be exposed to excessive levels of diesel particulate matter (DPM) before the problem is identified. To remedy this, researchers from the National Institute for Occupational Safety and Health (NIOSH) are seeking to develop a field-portable method for measuring elemental and organic carbon in DPM aerosols. In the current study, we investigated the use of Fourier transform mid-infrared (FT-IR) spectrometry, which lends itself more readily to implementation in a real-time system than do the thermal-optical analysis methods. We have demonstrated a method for measuring organic and elemental carbon in DPM for a broad range of organic carbon (OC) to elemental carbon (EC) ratios (from 50.3 to 0.8). The ability to handle a wide range of OC to EC ratios is critical given the evolving diesel technology. INTRODUCTION Respiratory illnesses are common in mining industry workers [1] and exposures to toxic aerosols such as DPM can result in serious respiratory illness [2]. Health studies show a correlation between workplace exposure to diesel exhaust and an increased risk of lung cancer [3-8]. The International Agency for Research on Cancer (IARC) has characterized diesel exhaust as a human carcinogen [9], and similar classifications have been made by the World Health Organization and the California Air Resource Board. A recent study [10] suggests that the risk of lung cancer is approximately three times greater for heavily exposed workers. When compared to other aerosols in the mine environment, the settling time of DPM is significantly longer than that of dust due to their small particle size (typically < 1 µm) [11]. Additionally, submicron particles (such as DPM) are deposited in the lungs much more efficiently than their larger counterparts such as dust [12]. Previous studies focusing on particle morphology [13] show that the largest mass contributor to lung disease in mining is elemental carbon, which provides a solid core onto which hydrocarbons are adsorbed. In accord with those findings the Mine Safety and Health Administration (MSHA) decided on submicron total carbon as a surrogate for monitoring diesel particulate matter in the mining environment."

Jan 1, 2018

By John E. Urbanic, William D. Faulkner, Robert W. Ruckel

Guidelines are presented for the selection, handling and regeneration of activated carbon used in gold recovery operations. The guidelines are based on Calgon Carbon Corporation&apos;s own investigations and experience gained in working with gold mine operators all over the world. Gold adsorption rate and adsorption capacity are shown to be independent variables thereby requiring testing of both properties when selecting activated carbon. Means of measuring these properties are provided. Historical activity tests on activated carbon are shown to be minimally useful in selecting carbon for gold recovery. Proper thermal regeneration techniques to maximize recovery of adsorption rate without weakening the carbon structure are suggested. Simple positive means of measuring efficiency of regeneration are presented. The subject of hardness measurement as a predictor of "in process" abrasion is discussed. The cost/benefit issue of carbon activity level is addressed.

Jan 1, 1986