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By W. J. Nosek

Reserve Mining Company completed construction on a major process modification project in June of 1980. These modifications enabled Reserve to reduce and control its final iron ore pellet silica content from 9.0 20.77 percent to 5.0 50.26 percent. The paper outlines the implementation of neutron activation on-line analysis and associated computer control loops for measuring and closely controlling the silica content of the iron ore concentrate at Reserve Mining Company. It contains a general overview of Reserve's taconite processing facilities and a presentation of the theory and operation of the neutron activation analysis equipment coupled with the computer silica control loops.

Jan 1, 1983

By T. J. McKeon

Partition curves are used to evaluate the separation performance of gravity-based concentrators. The partition curve is used to identify the nominal density cutpoint and relative sharpness of the separation. In addition, the graphical representation makes it possible to quickly identify the root cause of misplacement based on the characteristic shape of the partition curve. Partition curves have been traditionally constructed using data obtained from float-sink tests using heavy organic liquids. These toxic liquids are environmentally unfriendly and have been banned in several countries. Another method of establishing the partition curve is to introduce density tracers into the feed and plot the distribution to the lights and heavies. For heavy mineral separations, this approach is generally impractical due to the fine particle size. In addition, the partition data obtained using these existing techniques do not account for secondary factors such as particle shape that may influence the separation. In light of these problems, a methodology was developed for constructing partition curves using experimental data obtained from microscopic grain-counts. This technique, which essentially uses the different mineral species as density tracers, provides a powerful tool for evaluating heavy mineral separations. A case study is provided to demonstrate how this analytical approach can be used to assess and improve the separaton performance in an industrial upgrade plant.

Jan 1, 2005

By Charles H. Rice

Coal liquefaction processes can be divided into two broad classifications - direct and indirect. Direct liquefaction processes, in general, slurry coal with a solvent and react it with hydrogen under elevated temperature and pressure. Indirect liquefaction is the term applied to processes in which coal is first gasified to generate a synthesis gas of carbon monoxide and hydrogen. The synthesis gas is then converted to various types of liquid fuels by the proper selection of catalyst and conditions. The first experiments on direct coal liquefaction were undertaken in 1933 by Bergius. Development and commercialization of the Bergius concept was accomplished mainly through the effort of I.G. Farben at the Ludwigshafen plant of its subsidiary, Badische Anilin und Soda Fabrik A.G, under the leadership of M. Pier (1). A demonstration plat having an annual capacity of 100,000 tons of coal was built in Leuna, Saxony in 1927. Six years later, Imperial Chemicals Industries, Ltd., commissioned a plant in Billingham, England (2).

Jan 1, 1981

By J. W. Craven, M. Katom, K. M. McCaffery

At Ok Tedi, ore type and SAG feed size distribution vary widely and frequently. This makes control of the SAG mills by application of the power/pressure relationship difficult. Power logic has traditionally been conservative due to power spikes associated with rapid size distribution changes. A new expert system was installed in early 2000. The system incorporates multiple state fuzzy logic to deal with frequent and radical ore type and size variations, along with monitoring of motor temperatures. A short term power spike no longer warrants immediate radical action. This has resulted in increased mill throughput and improved circuit stability.

Jan 1, 2001

By G. L. Mowrey

One critical element of the U.S. Bureau of Mines (Bureau) autonomous mining research program is the development of a reliable coal interface detection (CID) system. Several candidate CID concepts currently being investigated by the Bureau include vibration, passive infrared, radar, and natural gamma radiation (NGR). To establish which CID sensor technologies need to be developed for a given seam, coal and adjacent rock samples (i.e., immediate roof and floor) are being collected from selected major coal seams in the U.S. and are being analyzed in terms of NGR and other geophysical measurements. Results of the NGR measurements indicate that, in general, all shale and shale-like materials (e.g., drawslate, slate, and fireclay) have higher NGR readings than the coal seam. Consequently the NGR method appears to be a potentially useful CID tool, provided that the immediate roof and floor are both composed of a high percentage of shale-type material.

Jan 1, 1990

By E. Bauer, S. Moore

Technological advances in underground coal mining have led to a reduction in fatalities. This study demonstrated that the percentage of cumulative injuries remained largely unchanged across two decades of technological advances (1983-1984: 37%; 2003-2004: 33%). Furthermore, it was demonstrated that the average number of lost days due to cumulative injuries has increased (36±55 days and 62±82 days, respectively) which may have been due to the increased age of the work force or an increase in length of employment meaning that the mine workers injured in 2003-2004 had been exposed to ergonomic risk factors longer than those in 1983-1984. It is recommended that ergonomics processes be implemented as a means to systematically identify, prioritize, and resolve the root causes of these cumulative injuries.

Jan 1, 2007

By A. J. Stewart, M. Guay, J. W. Critchfield, A. P. Hoddeson

The MetroWest Water Supply Tunnel project includes three main work shafts, excavated primarily in rock. Shaft L is 9.8 m (32 ft) diameter and 124.1 m (407 ft)deep. Shaft E is 7.0 by 12.8 m (23 by 42 ft) and 91.4 m (300 ft) deep. Shaft 5A is 7.9m (26 ft) diameter and 72.5 m (238 ft) deep. Construction methods are compared and contrasted. Lessons learned involve a differing site condition in soil overburden, contractor-proposed modifications, and remedial slurry wall work. Other aspects discussed include noise and vibration control, groundwater inflow, water treatment, muck handling and contract administration issues.

Jan 1, 1999

Newmont has been producing gold from the Carlin Trend for over 45 years. Naturally the focus, scale and complexity of the operations have changed considerably over this time. Newmont discovered and developed the Carlin Main ore body which is located about 32 km (20 miles) north of Carlin Nevada. The property was developed as a one mine one gold mill treatment plant operation which produced about 6,200 kg (200,000 Troy ounces) of dorè gold bars per year. The initial mine, mill and gold refining facilities were relatively small in comparison to today?s standards. The milling circuit used the Merrill-Crowe zinc precipitation process to recover dissolved gold and prepare a concentrated precious metal ?precipitate? to be melted into a dorè bar for sale.

Jan 1, 2012

By Lee W. Saperstien

At the heart of the mining process are a number of basic and fundamental tasks whose regular and repeated performance constitute the mining cycle. As will be discussed presently, these tasks are the basic components of the mining system. Section 9, Production Operations, provides the mine designer and engineer with an understanding of these tasks and with sufficient design principles to allow this person to create an efficient mine system. This section is meant to be an introduction and adjunct to subsequent sections that describe specific mining systems. However, sufficient design information is included here for the independent design of mine systems that may not be described elsewhere or for subsequent verification of existing designs. For the purposes of this section, mining subsumes excavation; thus this material applies to any excavation process. Accordingly, this section is written in general enough terms to include both surface and underground mining. It may be used also for civil engineering excavations that often involve the same steps. Obviously, the actual procedures undertaken in any specific mining system will appear to be very different from those taken in any other system. This is certainly true when comparing surface with underground methods. Yet the fundamental principles are often the same. This segment is written to explicate the basics. Wherever appropriate, the section will suggest the differences between the application process to surface or to underground mining.

Jan 1, 2008

By M. Gomilanovic

The Republic of Monte Negro (a member of the Serbia and Monte Negro federation) has 26 different mineral raw materials, 4 of which are recoverable and 22 unrecoverable. At present, 12 types of mineral raw materials are exploited. Based on these resources more than 80 facilities were built for the production and processing of mineral raw materials. The most significant of them are coal, bauxite and decorative and technical stone. Bearing in mind that all the mentioned mining facilities have significant impact on the living environment, and that Monte Negro was declared the ecological state, the objective of this paper is to present the experience acquired from this field of science.

Jan 1, 2003

By Bahram Sameit

Blast engineers have been taking advantage of image-based rock fragmentation analysis methods for the past three decades to estimate rock size distributions. These methods utilize a range of image segmentation techniques, from manual to fully-automated, to delineate the edges of rocks in images. Rock delineation results are then converted to physical rock sizes (and percentage passing curves) by scaling the image pixels to correspond to physical measurements. The size scaling process is critical for acquiring physical measurements, but specifc to the limitations of different applications. This article starts by presenting a shovel bucket-based fragmentation analysis system, where scaling is done using the known width of the shovel bucket within the image. It will then describe methods that use pictures captured by digital cameras with scaling reference objects in the view. Finally, the article presents a method that uses three-dimensional imaging to capture images without the need for scaling reference objects.

By G. Kim

The influence of bacterial growth phase on the flotation behavior of malachite has been investigated in a well-controlled Hallimond tube system. The microflotation tests were conducted for malachite (45?53 µm) using different amounts (bulk phase concentration=1×108?5×109 cells/mL) of Rhodococcus opacus (R. opacus) as a collector, which was grown at mid-exponential versus stationary phase, at a constant speed (340 rpm), pH (6), and malachite-bacteria interaction and flotation time (each 10 min). Hug differences between R. opacus cells in mid-exponential and stationary phase was observed from the results for electrophoretic mobility and flotation tests. Specifically, the isoelectric point of the cells in the stationary phase was lower than that in the mid-exponential phase, suggesting that the amount and distribution of surface functional groups onto cell surfaces are likely different. Additionally, the cells in stationary phase led to significant increase in the flotability compared to those in mid-exponential phase over the background bacterial concentration level of 1×108?5×109 cells/mL. Furthermore, the flotation efficiency tended to increase with increasing cell dosage for stationary phase cells while no distinct difference was observed for mid-exponential cells.

Feb 27, 2013

By D. J. Pandelis, W. J. Schlittler

Auxiliary Equipment pumping systems to support primary, secondary and regrind grinding circuits will be the primary focus of this paper. Every grinding system is unique and requires special design considerations for proper application of pumps to transport mill discharge. To satisfy the majority of applications, a new series of pumps has been developed by Svedala, known as World Class Pumps. Selection of these newly developed pumps for each type of grinding circuit will be presented. Specific components of selection are materials of construction, piping system, classification method, material characteristics and slurry characteristics. Both horizontal and vertical pump applications will be reviewed with emphasis on rules of pump piping and sump design.

Jan 1, 1999

By R. C. Milici

The primary factors that determine the marketability of coal from various supply centers in the U.S. are coal quality and supply; i.e. low sulfur, moderate- to high- Btu coals have large market areas when compared to less expensive but poorer quality coals. Price is the major factor in the competitive marketing of similar coal products. Good quality, (moderate- to high- Btu, low sulfur) coals from the Powder River and central Appalachian basins are marketed over large areas of the country, and central Appalachian coal is widely distributed in foreign markets, primarily as coking coal. In contrast, poorer quality bituminous coal (low calorific value and/or high sulfur) from the Illinois Basin, northern Appalachian Basin, and lignite from the Gulf Coast is marketed in or near the States in which it was mined even though the price at the mines may be lower than mine prices for central Appalachian coal. Widespread distribution of sub-bituminous Powder River Basin coal is enhanced by its exceptionally low mining costs, which offsets transportation costs to distant markets.

Jan 1, 2001

Partition models are commonly used to assess the separation performance of circuits incorporating density-based processes. Unfortunately, this useful tool has traditionally been overlooked by the heavy minerals sands industry due to difficulties associated with the use of toxic dense liquids. In the present study, this problem has been avoided via the development of partition models based on experimental data from microscopic grain-counts. This technique, which uses different mineral species as density tracers, provides a new tool for evaluating the multi-stage circuits that are required to successfully upgrade heavy mineral sands. The partition model approach easily identifies shortcomings of existing circuits and, when used with conjunction with linear circuit analysis, provides tremendous insight regarding the optimum arrangement of unit operations in terms of separation efficiency and plant throughput capacity. An industrial case involving the redesign of a heavy mineral sand spiral plant is presented to demonstrate the utility of these process engineering tools in plant optimization.

Jan 1, 2009

By Jr. Goller

You and I can visit cement plants, inspect the various rotary kiln systems and find some equipment or some burning techniques that waste energy--fuel and power. After we have made such a visit and studied a few ideas, we could recommend ways to eliminate much of this waste. Probably every idea would cost money to bring into action. For our discussion, let us arbitrarily set an upper limit of $1,000,000 on the recommendations that we are allowed to make. Call these "low-cost" or "short-term" measures. They are improvements that do not require more than say, three months to complete; they do not require a major revision to the process. Other recommendations are "high-cost" or "long-term"; they are outside the scope of this discussion. Some of our "low-cost" recommendations would offer a satisfactory return on the money that they cost; the remainder would not. Now, is there some way that we can rather quickly pick out the "low-cost" measures that will show a satisfactory return and spend our time making these improvements first? Can we separate these items from those where the return is less likely to be good? I feel that we can pick some of these items quickly if we have a kiln system that has consistently non-uniform day-to-day operation. If the operation is uniform we probably cannot pick them quickly.

Jan 1, 1977

By E. Cho

Illinois No. 6 coals of IBC 101 and IBC 112 were treated in solution with sodium hypochlorite to remove their sulfur contents, especially organic sulfur. The lab experiments were conducted in two steps of leaching at room temperature and hydrolysis at 90oC. The removal of organic sulfur from IBC 101 was by 37.8% while that from IBC 112 was only 13.7% under their respective optimum conditions. This large difference in organic sulfur removal is considered to be due to difference in concentration of surface total acid group, 3.14 vs. 0.88 mmol/g of coal.

Jan 1, 2007

By Rick Coleman

PT Freeport Indonesia’s (PTFI) latest expansion has increased total mill throughput to 125kt/d (137,700 stpd). The most recent expansion included the installation of a semiautogenous mill (SAG) designed to treat more ore than any other single SAG mill currently operating in the world. Also included in the expansion were two large ball mills, rougher and cleaner flotation, including conventional and column cells, and a regrind circuit. All equipment is supported by a modern distributed control system. PTFI’s operations are located in the Ertsberg mining district of Irian Jaya’s Jayawijaya Mountains, the eastern-most province of the republic of Indonesia on the Island of New Guinea. PTFI, the operator, is owned by Freeport McMoRan Copper and Gold (81.3%), the government of Indonesia (9.4%) and private Indonesian investors (9.3%).

Jan 1, 1996

By M. Karmis

The algorithms for the mathematical modeling to predict productivity of underground room-and-pillar mining systems are well known and documented. These algorithms consider the time-varying relationships between mining equipment for a given geometry of operations as well as other constraints. This paper presents WebConSim, a newly developed, Web-based, user-friendly computer simulation tool for the Windows environment. The simulator is easily customized for use by field engineers, planning engineers, and management and will help mine operators plan the optimum mining sequence for different mine geometries and equipment layouts. Program output includes production data and equipment utilization indices, as well as time driven event chains that can be used for virtual reality presentations.

Jan 1, 2001

Due to deposit shape and dimension, narrow vein makes reserve modeling, geological control, stope design, drill and blasting more challenging. It needs high standard quality control as errors can be created easily, which could cause significant amount of ore loss or dilution. From channel sampling, survey control, reserve modeling, drill hole design, blasting, communication with underground drillers to backfill, this paper illustrated every step and its quality control of a long hole stope mining. Compared to other narrow vein mining methods (cut and fill and shrinkage), long hole stoping means higher production, less labor, and significantly lower cost when deposit characteristics allowed.

Jan 1, 2012