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By Steve Van Kouteren

Filters and absorbents purify, clarify, and clean many types of liquids by removing solid particles. In addition, absorbents provide a convenient way to handle liquids and to clean up liquid wastes or spills. Filtration or absorptive processes are accomplished either in a mechanical way, as in absorption and filtration, or in a chemical way, as in adsorption. In filtration, minerals and rocks used as filter mediums are extensively utilized in applications requiring the filtration of high volumes of liquids. End use applications include liquid food products, waste waters, petroleum and chemicals, and drugs and pharmaceuticals. Upon closer examination of all of the materials used as filters and absorbents, industrial minerals and rocks represent only a small proportion of the total amount, as shown in [Fig. 1] (Rees, 1991). Given all the industries that use these minerals, most of the volume is concentrated in a few major end-use markets. Within these major end-use markets, a handful of minerals account for most of the total volume and value. The focus for this chapter will be to discuss the industrial minerals and rocks used as filters and absorbents in the most important markets. The selection of the minerals and markets to review is solely based on the total volume of material used and in special cases, those where the value of the market and material is high. The major materials include diatomite, perlite, sand, gravel, and such specialty clays as montmorillonite and attapulgite. These materials are mainly used for the filtration of food, chemical, and petroleum products. In addition, they are used as absorbents for pet litter and oil and grease spills, and as carriers for pesticides and fertilizers.

Jan 1, 1994

By Dennis P. Bryan

The southwestern United States has an abundance of natural lightweight aggregate (NLA) deposits of volcanic origin that are being used in the construction industry within the region. New Mexico, Arizona, Nevada and California utilize NLA in portland cement concrete and concrete masonry units for weight reduction and related economic reasons. The geological environment of the western United States is amenable to the occurrence of natural lightweight rocks because it contains Tertiary and Quaternary volcanic products that include low-density glass and vesicular material. There are two major classical types of natural lightweight materials of igneous origin; pumice and cinder. These account for the vast majority of volcanic rocks that are presently utilized as NLA. Pumice is an ejecta product generally found as part of tuffaceous units associated with nearby siliceous volcanic centers. Cinder, also an ejecta product, is associated with mafic volcanics and is most often found as a cinder cone. Both are highly vesicular. A third type of natural lightweight material, though also associated with siliceous volcanics, is less vesicular than pumice. It is best described as being a slightly pumiceous rhyolite or rhyolite-tuff breccia that occurs as a siliceous dome or tuft unit that is most likely to be glassy. Uses of these natural lightweight rocks center on the construction industry where they are utilized in lightweight portland cement concrete and lightweight concrete masonry units. The major reason for usage in portland cement concrete is cost saving effected by weight reduction in high-rise construction. The major usage in concrete masonry units, or "block", is for weight reduction that enables a mason to lay more lock.

Jan 1, 1987

By H. Colijn

Introduction Bulk commodity prices are ever increasing. This forces buyers and sellers in world markets to look more carefully at methods for obtaining an accurate accounting of commodity transactions in commerce and materials utilization in processes. Weighing and sampling inaccuracies can result in loss of income, product quality, and cost controls. So weighing and sampling accuracies are extremely important. They are the key components of managing the quantity and quality control aspects of bulk materials handling. This article will confine itself to the weighing systems and will deal with various aspects of system design, calibration, and operations. Emphasis will be placed on new developments and requirements in this field. Weighing methods To measure the gravimetric pull on a body being weighed (the load), the gravimetric force must be countered by an opposing force. Measuring this counter-balancing force thus becomes the measurement of weight. The conventional even-arm balance shows the concept of balancing an unknown mass with an equal known counterbalancing mass. But the loads encountered in industry generally range up to many thousands of pounds. So it is obvious that the even-arm approach is not practical. Thus, with the exception of direct load-bearing load cells, most of the weighing equipment uses some form of lever system. This is usually a combination of first- and second-class levers, to gain a mechanical advantage. These levers permit the load force to be counter-balanced and hence measured within a practical range. Lever systems not only perform this force-reducing action, they also serve to focus the load force at a single point, for convenient measurement. They align the force vertically in one direction so that measurement accuracy will not be affected by unrelated side forces. There are five basic methods of gravimetric weight measurements. That is, there are five basic types of opposing forces. • The first is the standard weight counterbalance. It uses a known weight to counterbalance the load directly or through a lever system.

Jan 9, 1988

By L. A. Puchkov

Problems of how to use artificial intelligence (AI) methods and expert systems (ES) to control complex industrial projects have lately become significant in practical terms. Mining ventilation systems undoubtedly belong to complex multi dimensional objects of control with stochastic nonstationary and nonlinear processes. Formal models based on automated ventilation control, do require awkward algorithmic solutions, moreover, a number of tasks become the operator's headache, and the quality of their solution depends on his experience and intuition. These tasks include: - identifying pre-accidental situations and determining their causes; - making well-grounded decisions with regard to changing ventilation regimes, forecast of mining operations taken account of; - controlling ventilation systems in emergency situations, e.g. when in accident, etc. It is in this context that we have for a number of years been investigating how to practically use AI methods for operative control in dynamic aero-and-gas mining processes, one of our research directions being devoted to working out a consulting programme for the ventilation system operator. Our researching and modeling problem was identification of aero-and-gas situation in different parts of ventilation network and its interpretation in order to determine possible causes for gas regime changing and unexpected consequences. We would single out the following stages in this task: I. Operative information procession coming to the data base from the sensors and analysis of hypothetical versions (using the associative rules base) with regard to factors which have caused significant parameter fluctuations (e.g. C%(t), H(t), Q(t) etc.)., 2. Selection of hypotheses in the knowledge base and forming conclusions in accordance with reliability scale. 3. Clarifying the obtained conclusions in dialogue with the operator. 4. Correcting the associative rules base.

Jan 1, 1992

By J. Stachulak

This paper deals with theoretical considerations and practical applications of ventilation network calculations, based on mass flow rates and performed by computer simulation in our deepest operating mine - Creighton. The paper also deals with natural ventilation. In the usually accepted air-flow theory, the air is assumed to behave like an incompresssible medium. This introduces considerable error where temperature and pressure changes are great. Therefore, any study of the air flow in deep mines, must take into account compressibility. Basing ventilation calculations on mass flow allows a distinction to be made between air leakage and such quantity changes which occur due to air density changes. The energy which is required to convey one pound of air through a mine can be obtained by adding all head losses hL (ft-lb) of the ventilation paths through which the air flows. However, this total energy will not be correctly expressed in a compressible fluid by summing all pressure losses PL = hL x d (ft-lb/ft3 = lb/ft2) d = density. There is a law of mass conservation, but no law of volume conservation. Natural ventilation is caused by the conversion of heat into mechanical energy and not by the difference in upcast and downcast densities, as often believed. In an existing mine natural ventilation can be determined correctly by plotting a pressure volume diagram and measuring the area ? [ ] vdP = hN, where v = specific volume, or by measuring the sum of all friction losses and work provided by a fan. These procedures are tedious. The natural ventilation head (hN) can be approximated by the equaticn hN =[ ] tdZ. Where T is the average absolute temperature, t air temperature and Z elevation. In Prof. R. Greuer's computer program this determination of hN is automatically done for every mesh of the network.

Jan 1, 1980

Production In 1993, it was estimated that United States mine production of barite increased 24%. Barite consumption, either sold or used by grinding plants, increased by 39% and imports increased 4%, according to the US Bureau of Mines (USBM). Nevada continued to be the leading producer of barite with 80% of the total, followed by Georgia. It is estimated that 83% of the domestically mined barite was used as a weighting agent in drilling fluids. The remaining 17% was used in barium chemicals, glass or as a filler. Most of the production from Missouri, Georgia and Tennessee was used in the non-oilfield sector. Prices The value of domestically produced barite, f.o.b. mine, decreased 1%, according to the USBM. The declared value c.i.f. US port of all imported crude barite during 1993 decreased from $40.09/t ($36.37/st) in 1992 to $37.72/t ($34.22/st). Uses Of the total barite used by grinding plants and chemical manufacturers, it is estimated that 90% was used in drilling fluids and 10% in the non-oilfield sector. This included barium chemicals, fillers in paper, plastics, brake shoes and glass. The tonnage consumed in the drilling fluids market increased due to the higher average rig count during 1993. The average number of rotary rigs operating in the United States was 754, 5% greater than the 1992 average of 717. Imports Crude barite imports in 1993 were 443 kt (488,000 st) greater than 1992, representing an increase of 137%. Imports accounted for 67% of the barite consumed (apparent) in the United States.

Jan 1, 1994

By L. B. Kirk, A. R. Kirk

At New World, Au-Cu-Ag mineralization occurs in stratiform car-bonate-hosted, massive sulfide-iron oxide, and skarn-replacement deposits. Regional pyritic-alteration, local massive sulfide mineralization and mine wastes generate acid drainage within the district. Water quality improves down gradient through dilution and mixing of acid and metal-rich mine water with bicarbonate-rich, low-metal surface and groundwater, and precipitation of metal-rich ferrihydroxide phases. Natural deposits of ferricrete indicate that pre-mining ARD has occurred, providing important clues to pre-mining water quality. The geoenvironmental model identifies the Cu-skarn mineralization as the primary target for ARD management. Closure success will be limited by the geoenvironmental nature of the natural mineralization.

Jan 1, 2004

By J. I. Schoenherr, G. Schubert, T. A. Baloun

The currently known and used plastics and rubber recycling or sorting processes cannot be applied efficiently and economically due to large amounts and different numbers of plastics types as well as of fine bulky materials (<4mm). These wastes are mostly given to land-fill sites. Thermal adhesion seems to be a great means to efficiently separate plastics mixes. Tests carried out at a special lab-scale testing unit (TaA1) confirm the effectiveness and feasibility of the separating mechanism. The thermal properties of the individual types of plastics differ from each other to a sufficient degree so that special products or product mixes of high material purity can be obtained according to the respective requirements. For this reason, plastics mixes such as PE and PP can be sorted with very good results. The separation efficiency is influenced only by different contact surfaces. The contact period can be adjusted to a short period of time so that sorting large amounts of fine dispersed plastics seems feasible. Sorting processes in feed streams were shown to be technologically effective when applying appropriate technologies. For the time being, the technological application of a thermal adhesion drum separator (TaTr1) is suitable. First tests on such a pilot-scale unit provided good separation results.

Jan 1, 2004

By Fred Leighton

INTRODUCTION Dynamic (seismic or microseismic) methods of determining the stability of structures in rock are based on detecting and analyzing the characteristics of seismic energy that has originated from or traveled through the rock mass. This seismic energy can be in the form of naturally occurring rock noise energy resulting from structural adjustments within the rock or can be introduced into the structure by physical means, such as by blasting or impact. In either case, the seismic energy radiating through the rock mass can be detected using standard equipment and can be analyzed by established techniques to reveal a wide variety of information concerning the condition and stability of the rock mass through which the energy has traveled. In the following sections, the basic instrumentation required for seismic and microseismic studies is described, and some of the presently used applications of these methods are discussed to exemplify the state of the art. INSTRUMENTATION Seismic disturbances in a rock structure generate two types of seismic wave radiation, body waves and sometimes surface waves, which radiate outward in all direc¬tions from the source of the disturbance. Underground mining applications are generally concerned only with discerning the characteristics of the resulting body waves, i.e., the compressional (p-wave) and the shear (s-wave) energy. As these two forms of energy travel through the rock structure, the particles of the rock mass are caused to vibrate, and the vibration character¬istics resulting from each of the two types of wave are distinct. Some important differences are: 1) Compressional and shear waves travel at different velocities through the rock structure. 2) The frequency at which each wave causes particles to vibrate is different, and may range from about 50 to 100 000 Hz. 3) The amplitude or energy level of each wave is different, with the shear energy usually being the greatest. These differences form the basis for equipment se¬lection for individual studies and for modern data analysis techniques. The following sections describe the basic equipment necessary to detect and record seismic wave energy data and show several examples of analysis procedures and how these procedures have been used. In principle, seismic equipment is very simple. It consists of a geophone (or geophones) to detect the seismic energy vibration and convert that vibration to an electric signal, an amplification system to increase the level of that signal, and a means of monitoring and/or recording the signals detected. Fig. 1 is a block diagram of a typical system. The following sections offer a very brief discussion of system components and their individual functions. A more complete discussion is given by Blake, Leighton, and Duvall (1974). Geophones The function of the geophone is to detect the vibrations caused by the passing of the seismic wave energy and to convert that vibration into an electrical signal that displays both the amplitude and frequency characteristics of the vibration. Particle motion or vibration can be quantified and measured by measuring displacement, velocity, or acceleration of the particles. Thus, there are three types of geophones: displacement gages, velocity gages, and accelerometers. The choice of gage depends on the characteristic frequencies of the seismic energy to be monitored and the sensitivities of each type of geophone. In general, displacement gages are used for low-frequency monitoring (periods to 1.0 Hz), velocity gages for medium-frequency monitoring (1.0 to 250 Hz), and accelerometers for high-frequency monitoring (250 to 10 000+ Hz). Experience has shown that in underground studies, the choice of which gage to use lies between velocity gages and accelerometers. An easy, accurate method for selection of gage type is discussed by Blake, Leighton, and Duvall (1974). Once the type of geophone has been selected for use, it must be properly installed, and in the installation procedure the most important step is insuring that the gage is firmly attached to a competent portion of the rock structure. Poorly mounted geophones may entirely fail to recognize low-level seismic signals and will distort the information from signals they do see. Amplifiers Seismic events associated with mine structures occur over a very broad range of energy which results in a broad range of geophone output levels. In general, geophone output levels occur in the microvolt to low milli-volt range, and it is necessary to amplify these signals in order to drive recording or monitoring equipment. Because either an accelerometer or a velocity gage might be used as the geophone, the amplification system must

Jan 1, 1982

By Hesam Dehghani, Farid Alimohammadnia, Nima Babanouri, Mokhtar Kalhori

In open-pit mining, blasting pattern design is performed to achieve a desired degree of fragmentation for loading, hauling, and crushing operations. Inappropriate fragmentation of rock will result in numerous problems such as incurring extra costs for secondary blasting, production interruption, etc. Wetness of the blast holes is one of the most important factors, which can cause the inappropriate rock fragmentation. Lowering ambient temperature in the vicinity of the explosion, the presence of water in the hole adversely affects the quality of the explosive while dissipating part of the explosion energy, ending up with inappropriate fragmentation problems. In the present research, in order to study blast-induced fragmentation conditions in Baba-Ali Iron Ore Mine, three scenarios were considered: explosion of ammonium nitrate with fuel oil (ANFO) in dry hole, explosion of ANFO in wet hole, and explosion of the emulsion in wet hole. For this purpose LS-DYNA, a numerical simulation code was used. Results of the present research showed that, compared to the explosion of ANFO in wet hole, the explosion of the emulsion produced more uniform distribution of fragment size, while the explosion of ANFO in dry hole resulted in fewer large fragments.

By J. den Drijver, M. Opahle, R. Inderst

Safety reasons render necessary the advanced calculation of the amount of methane degassing from a longwall in the scope of the ventilation planning of mines. Today empirical methods, which are based on observations of operational procedures, are used for the calculation of the amount of methane. Despite of constant improvement those calculations are not always sufficient. In particular calculations which are based on operational facts but not proved by experience are not reliable. Most of all these calculation procedures lack physical-analytical descriptions of the procedure itself, presenting only the effects on important parameters such as the distance between seams in the roof or floor or gas pressure. Tschersich [Tschersich 961 developed an analytical model for an advanced calculation by analysing the degassing of seams in the roof and floor and the physical parameters of gasflow. This model might correct the lacks of existing procedures and improve the precision and reliability of additional calculations. The model simulates the emission record in seams of the roof and the floor. It takes into account not only a multitude of parameters such as the distance to adjacent seams and gas pressure but also the depth of seams, gas content, rank of carbonification, rock temperature, face advance rate, initial and succeeding mining and the face length. In order to comprehend and to verify those correlations we extended the model of Tschersich and programmed this enlarged model using the computer language C++. Aim of this research is to guarantee a much higher accuracy in calculating methane emission caused by mining. The improved planning is expected to result in more safety and better prevention of high methane con- tent in ventilation as well as in a better use of the capacity of the mining equipment. The application [Drijver, lnderst 961 of the ex- tended model will also be very useful in the course of research projects as it allows computer simulation, i.e. in-situ research can be extensively limited or even replaced.

Jan 1, 1997

By N. Ohmura, H. Saiki, T. Nagaoka

A microbiological flotation system that facilitates the removal of pyritic sulfurfrom coal is reported. The chemoautotrophic bacterium Thiobacillus ferrooxidans is utilized as a pyrite-selective biological surfactant that augments the flotation-mediated rejection of pyritic sulfur. The bacteria were produced by continuous cultivation in 50-L tanks, where it was possible to produce 3.8 x 1012 cells/day when the dilution rate was optimal and the pH was 1.6, a condition that prevented ferric precipitation. Prior to flotation, the bacteria were mixed with coal, which allowed cells to selectively adhere to the pyrite. The adherence of bacteria made the pyrite surfaces more hydrophilic, which facilitated separation by increasing the tendency of pyrite to sink, while the hydrophobic coal floated. When a synthetic coal/pyrite mixture (10.1 % sulfur) was subjected to microbial flotation, the level of sulfur rejection was stable during the entire period of operation (i.e., one hour). In the absence of bacteria, flotation reduced the sulfur content of a coal/pyrite mixture to within the range of 6.7% to 7.4%, with the combustible recoveries ranging from 93.9% to 99.0%. In the presence of bacteria, the sulfur content of cleaned coal was in the range of 1.3% to 1.4%, with the combustible recoveries ranging from 80.8% to 86.3%. Bacterial activity accounted for 57% of the total sulfur rejected through flotation. The desulfurization capacity of the system was further confirmed by testing it with run-of-mine coal. The pyritic sulfur content was reduced from 2.9% in the feed coal to around 1.2% in the froth product, while 80% of the combustible recovery was retained. Microbial flotation removed 60% of the pyritic sulfur from the feed. These findings demonstrated that micro¬bial flotation could be utilized for the removal of pyritic sulfur from coal in a semicontinuous system.

Jan 1, 2000

By A. Gupta, S. C. Srivastava, K. K. Saroj

Bacterial degasification of methane and conventional methane drainage for generation of power have become accepted practice. Comparative economies of both the techniques have been described. Authors have discussed an alternative technique, involving complete methane biocycle. The first stage of the entire process involves gasification of coal using a consortia of bacteria to generate methane. The generated methane has been proposed to be pumped,as in conventional methane drainage. Technique described is basically similar to underground coal gasification, with the difference that in place of coal combustion, degradation of coal to lower molecular weight compounds by one set of bacteria and then methanogenesis by methanogens, producing methane have been described. Brief account of communities of bacteria that may be employed have been dealt with. Three arguments in favour of proposed technology as an alternative to conventional coal mining are: 1.Total elimination of hazardous operation. 2.Availability of power plants based on methane drainage, assuring comparative economies. 3.Possibility of utilisation of fuel cell technology for power generation giving higher efficiency. All the three phases of complete blocycle viz (1) methane generation from coal (ii) conversion of methane to hydrogen and oxygen (iii) conversion of products so obtained to methane, thereby completing the cycle have been discussed. INTRODUCTION Drainage of methane by conventional pumping process (Boxho,et.al.,1980) not only is helpful in maintaining safe extraction of coal, but with utilisation of extracted gas for power generation, also helps in over all economy of coal mining. This is gradually becoming standard practice for mining of coal in highly gassy mines. An alternative technique (Thakur et. al., 1991) of bacterial degasification of coal seams is also gradually gaining ground. The bye products of this process that is carbondioxide and water, do not contribute towards economy of coal extraction process. However the technique has its own advantage particularly in goaf area for avoiding fire hazard and drainage of methane from coal seams prior to initiation of mining operation. Either of these techniques could be applied in specific situations with success.

Jan 1, 1993

By Viacheslav Lyakhov, Cornelis H. Iestra, Victor I. Beloborodov, Vitaliy Bogdanovich

The results of a study and effective use of flotation for processing of ores with complex mineral composition containing fine-disseminated minerals with high specific density are presented in the paper. The object of research was complex baddeleyite-containing ore from Kovdor deposit (The Kola peninsula, Russia). Baddeleyite is a valuable, rare mineral, natural Zirconium dioxide with 5.8 - 6.0g / cm density, grade content 0.15 - 0.17 and dissemination less than 0.2 mm. The authors carried out a thorough investigation of baddeleyite- containing products selected in different sites of gravity flowsheet. It was determined that due to similar specific weight some sulphide minerals (pyrite, pyrrhotite) come into concentrate together with baddeleyite and, also, minerals of pyrochlores group (hatchettolite). The results obtained revealed the possibility of use the flotation for retreating rough baddeleyite concentrate. he given gravity concentrate has a number of specific features, e. g. high density of its minerals which, in its turn, provides for high speed of sedimentation of solid phase in pulp, and for the presence of large amount of sulphide minerals (up to 10%) having good flotability. With these features being taken into account a technology for flotation of baddeleyite-containing products after their preliminary gravity concentration has been developed (up to 5 - 10% Zirconium dioxide). The technology has three flotation stages. At the first one the reverse flotation of baddeleyite is carried out during which "light" minerals (forsterite. apatite and carbonites) come into froth product and at the second one flotation of sulphide minerals and at the third one direct flotation of baddeleyite is performed from the underflow product. The following reagents were used for flotation: of phosphate type (sodium tripolyphosphate, mono and diethers of alkylphosphpric acid) and sodium xanthate as collector for sulphides. The given set reagents provides for high effectiveness of flotation due to selective of collectors and presence of froth layer with high carrying ability. New flotation technology of recovering of baddeleyite from complex ore was developed and applied at the Kovdor Mining Plant, using AKER flotation machines.

Jan 1, 1995

By Leo Misagi

THE ROLE OF MANAGEMENT IN PLANT SAFETY Safe Production In plant management, safe production is an ideal. It becomes reality when: 1. Plant employees work in healthful and safe conditions. 2. Plant safety is in harmony with productivity. 3. Worker absenteeism and turnover are low-the work force is stable. Plant management must apply its talents, skills, and resources to build and maintain the foundations of safe production on a system of policies, procedures, and attitudes. It must do so by marshaling all managerial functions - staffing, direction, control, innovation, and representation-toward that goal. Ideally, a plant safety program is proactive. Management should plan and implement safety activities that are aimed at prevention. Past accidents-accomplished facts-should not be the sole guide of future actions. In other words, positive preventive measures, not the fewness of accidents are the criteria for safety production. An ideal safety program is one which is cost effective. Management should view plant safety as part of a broader program-loss control. Loss control includes prevention of fires and other accidents, unhealthful conditions, and occurrences that cause bodily injury, illness, property loss, or damage. Management evaluates the employees&apos; productivity and safety. An effective training program aimed at loss control is the hallmark of safe production. Ideally, both labor and management should be well versed in safety. They believe in the premise that work-related injury and illness, as well as property loss and damage from fire and other accidents, are manageable and preventable. Such belief prompts them to learn more about the work process and potential hazards associated with each job. They also learn how to expect and prevent fues and other accidents, and respond to emergencies at the plant. Plant management determines which individuals or groups of employees are accountable for the following functions:

Jan 1, 1991

By O. Ozcan, J. D. Miller, Z. S. Nickolov

The production of soda ash from trona (sodium sesquicarbonate, Na2CO3•NaHCO3•2H2O) resources has completely displaced the production of synthetic soda ash in the USA. Further, the utilization of other trona resources is under consideration in China, Turkey, etc. Recent research has been concerned with the development of flotation technology for the trona industry. In this regard studies on the flotation behavior of sodium carbonate salts: trona, sodium carbonate monohydrate and decahydrate, as well as the flotation behavior of sodium bicarbonate, are reported for both cationic (dodecyl ammonium hydrochloride) and anionic (sodium dodecyl sulfate) collectors. It has been found that strong flotation of sodium bicarbonate (NaHCO3) can be achieved with 100% recovery, while the other sodium carbonate salts do not float well. These results have been explained by FTIR analysis of aqueous solutions of Na2CO3and NaHCO3in a range of concentrations from very dilute to saturated conditions. The changes in the shape of the O-H stretching band of water are correlated with the flotation behavior of Na2CO3salts and NaHCO3. In addition, the absorption band of the carbonate ion at ca. 1385 cm-1is used to monitor its interactions with water and/or other ions in solution. The infrared results demonstrate thatNa2CO3acts as a water structure maker, leading to an extensively hydrated surface that accounts for the poor flotation of most sodium carbonate salts. In contrast, NaHCO3does not have this characteristic and consequently complete flotation is possible with both cationic and anionic collectors. These results support the previous water structure analysis for soluble salt flotation of alkali halides and other oxyanion salts.

Jan 1, 2003

By T. Ertekin, R. V. Ramani, W. Sung

The emission of methane in the coal mine working faces has two immediate impacts with regard to coal mine planning. Firstly, at the planning stage, the coal mine ventilation system must be designed such that airflows in the faces keep the concentrations of the gas in faces areas to below one percent. If the concentrations were greater than one percent, the production machine has to be shut down resulting in a loss of productive time. In an extreme case, concentration can reach explosibility limits which may lead to ignitions and explosions. Secondly, in excessively gassy coal seams, several alternatives can be applied to the mine layout configuration, and the mining method to be predicted for the extraction of coal, so as to insure a productive and safe operation. In this study a two-phase, two-dimensional finite-difference model was used to predict the methane emission rates into active mine working area under several methane drainage schemes. The numerical model utilizes a recently developed multi-mechanistic flow theory which describes the flow of methane in an heterogeneous and anisotropic coal seam. Transport of methane in the micropore structure of the coal is described by the Fick&apos;s law of dif- fusion under the influence of existing concentration gradient, while flow in the more permeable butt and face cleats (macropore spaces) is formulated by Dar- cy&apos;s law under the influence of existing pressure gradient. The desorption of the methane is accounted with the aid of a quasi-steady kinetic sorption model. A series of simulation studies were conducted in a systematic manner by sifting through the parameters associated with the coal seam characteristics and the degasification strategies in order to understand those which most significantly affect the methane emission rates in the face areas during mining. Along these lines, the effects of coal seam properties such as thickness, porosity, permeability, sorption characteristics and scheduling of drainage process against the mining operation have been isolated to understand the role of each individual parameter on the methane emission rates.

Jan 1, 1987

By R. A. Jankowski

Although the number of operating longwall mining systems has remained relatively constant, longwall production levels during the last five years have increased significantly. In the United States, longwall mining now accounts for approximately 50% of all 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 the 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, National Institute for Occupational Safety and Health, Pittsburgh Research Laboratory, examined several basic principles of the long wall 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 airflow and the entrainment and dilution of respirable coal mine dust. Studies have been completed to determine the impact on face dust levels of using belt entry air to ventilate the longwall. Novel methods have been identified to increase the face air¬flow and to manage face airflow to effectively minimize dust exposure to face workers. 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 1980s and 1990s, have reduced the health hazard associated with excessive exposure to respirable coal mine dust.

Jan 1, 2000

By Paul M. Jr. Musgrove, Donald C. Moore

Conventional Smelting Practice Conventional copper smelting practice varies from smelter to smel¬ter, but generally consists of some or all of the following unit processes: roasting, smelting, converting, and fire refining. Roasting. Copper sulfide concentrates can be smelted directly or after an initial roasting step. Roasting is used in some smelters because roasting prior to smelting increases smelting capacity, less energy is required to melt hot roaster calcines than wet sulfide concen¬trates, roaster off gases are high in Sot concentration, 5-15% SO2, and some volatile impurities are removed from the concentrate prior to smelting. However, many smelters do not use roasters, because the problems associated with handling hot dry calcines outweigh the advantages mentioned. Concentrate roasting is performed in multiple hearth or fluid bed roasters. If the moisture is low, roasting can be performed autogenously, usually at 500-600°C. High roasting temperatures are avoided because excess oxidation of the iron compounds may lead to magnetite formation. Magnetite is detrimental to reverb operation because mag¬netite can combine with refractory minerals to form a highly viscous slag. This slag prohibits efficient matte-slag separation and leads to excessive copper losses. Also, magnetite can settle through the matte layer, deposit on the furnace bottom, and consequently reduce furnace capacity. Roasting is carried out only on sulfide concentrates prior to smelt¬ing in reverb or electric furnaces. For smelting processes, such as the flash and continuous that rely on the exothermic heat of oxidation of the sulfur minerals, roasting is not practiced. Reverberatory Smelting. The predominate copper smelting fur¬nace for the past 50 years has been the reverb. These furnaces are typically 100-120 ft long, 30-35 ft wide, and 12-15 ft high. A typical furnace layout is shown in Fig. 2. Refractory brick linings cover all internal surfaces of the furnace. Originally the flame was directed to reverberate or reflect off the furnace ceiling and melt the feed material. Current practice is to direct the flame down the furnace length to melt the concentrate. A method of charging the concentrates or calcines, generally along the side walls to minimize refractory erosion, is incorporated in the furnace design. The copper concentrates, calcines, and fluxes charged into the reverb undergo a series of complicated reactions as the temperature of the mixture increases. The reaction of the iron and copper sulfides with the oxygen in the furnace produces a molten Cu25-FeS mixture called matte. Copper smelting metallurgy is based on the fact that sulfur has a greater affinity for copper than for iron and most other common metals. Therefore, in a system containing copper, the copper will preferentially remain as a sulfide compound until all of the other metals have been oxidized. The oxidized metals combine with silica to form a silicate slag that floats on the matte and is removed from the system. Reverberatory furnace smelting chemistry can be approximated by the following chemical equations: FeS2 + O2 - FeS+ SO2 (1) The formation of FeS ensures that any copper present other than as sulfides will be reduced by the relationship: CuO2 + 2FeS + O2 - CuS + 2FeO+SO2 (2) or 2Cu +FeS - Cu2S + Fe (3) As the molten charge travels down the furnace, continued oxida¬tion of the iron minerals and sulfurization of the copper minerals occurs. When all of the copper has been converted to sulfides, the iron sulfides can then be further oxidized as: FeS + (3)2 O2 FeO + SiO2 (4) The FeO reacts with the silica added as flux in the furnace charge. A simplified equation is: FeO + SiO2 -FeO SiO2 (5) The iron silicate slag formed is skimmed from the surface at the end opposite the burners. The copper content of reverb slag is usually less than 0.6% Cu and is discarded. Matte is removed along the side wall and is taken to the converter for oxidation of the remaining sulfur and iron. The main objectives in reverberatory smelting are to produce a molten Cu2S-FeS matte containing 30-60% Cu and a throwaway slag. Production of matte permits complete conversion of all copper minerals into copper sulfides, which can migrate because of specific gravity differences, through the lighter slag layer. Also, the molten matte droplets collect the noble metals, gold and silver, as the matte settles in the furnace. The large settling area of the furnace provides enough separation time to produce a low grade slag, which can be discarded without further processing. High heat losses are associated with reverberatory smelting be¬cause of the large volume of gases sweeping through the furnace. Therefore, an outside source of heat is required to keep the smelting reaction going. Natural gas, fuel oil, or pulverized coal are used as this heat source.

Jan 1, 1985

By Scott G. Britton

Today&apos;s coal mines are turning more and more to belt haulage as the key system to transport coal out of the mine. The advantages of using belt for both intermediate and main haulage are numerous. Belts are reliable high capacity haulage mediums that can be utilized at low operating costs. They are adaptable to rolls in the coal seam and can handle relatively steep grades. They are not noisy, operate with a minimum amount of labor, and are easily extended and retracted. Belts require the least power of any haulage medium, are easily controlled by push- buttons and interlocks, and present low fire and safety hazards. Belt haulage can also be the largest source of operational problems for mine management when not installed correctly. This chapter and Chap. 6 concentrate on proper installation of both the static and dynamic components of efficient belt haulage. This chapter looks at the static system component, composed of the belt drive, its installation and operation, as well as belt takeup and transfer point construction. These components do not change readily over the life of the installation, hence the term static system. Chap. 6 discusses the dynamic system of belt line construction, which includes belt splicing, breaking down and reanchoring the tailpiece, and extending the belt line, plus operational and maintenance items for belt operation. This chapter is divided into three major topics. The first is a general discussion covering the points necessary for designing an efficient haulage system; the second looks at installing belt drives, head rollers, and takeups, and the third discussion centers on installing efficient and effective transfer points along the haulage system. Each will address the design and construction issues facing the engineer or construction supervisor in charge of installing the system. Before looking at the static system, it may be useful to review some of the basic design factors and considerations of all belt haulage systems. The material usually carried on an underground belt is a mixture of raw coal and rock, commonly known as run-of-mine (ROM) coal. This mixture has certain material characteristics that guide the mining engineer to the final and proper belt selection. The characteristics looked at most frequently are: 1) Angle of Repose is the angle at which the material will freely make a pile. Most ROM coal averages a 35"-39" angle of repose. 2) Angle of Surcharge is the angle a pile will assume on a moving conveyor. This ranges from 5" to 15" less than the angle of repose in most materials. For ROM coals, 25" is the average angle of surcharge. 3) Flowability, which determines the maxi- mum cross-sectional area needed to carry any given material on a belt. It is measured by the angles of repose and surcharge of a material and also serves as an index of the safe incline angle for the belt line. These characteristics, plus practical engineering research and development work are defined by an organization called the Conveyor Equipment Manufacturers Association (CEMA) for most bulk materials. CEMA also provides a code for each classified material depending on the characteristics above and the subjective considerations of the average size to be encountered, the abrasiveness of the material, and any miscellaneous characteristics (oil resistive, corrosive, etc.) which may be important. For coal, CEMA (composed of member companies in-

Jan 1, 1983