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By Wendell H. Nielson

Flotation processes contain disturbances which make material balance closures difficult to achieve. Lack of closure also arises from instrument errors. A portion of these problems can be overcome by proper equipment selection; the primary measurement installation and methods of initial data filtering are discussed below. The problem of data adjustment has been considered before (2). The technique described here is essentially that of Ripps (2). The technique was expanded to include linearization of non-linear material balance equations. An additional large error detection portion was also added to Ripp's formulation. Ripp's technique is based on a Lagrange-Multiplier optimization method. The Lagrange-Multiplier technique is generally applied when there are equality constraints on the variables. Steady-state material balance equations fit in this category. The basic Lagrange-Multiplier method is described. It is followed by a description of the modified material balance data adjustment technique. An example is presented to illustrate the use of this method.

Jan 1, 1970

By Emanuele Catelli, Paolo Vicentini, Manuel Petitat, Paolo Lanfranchi

"More than 800 million tons of material will be excavated during large underground projects such as tunnels, undergrounds and power plants by 2030 in Europe only. The raw material excavated is often classified as waste, which involves environmental impact and transport issues: landfill areas, CO2 emissions and noise. But how can such massive amounts of material be transported, processed and deposited? Using the example of the AlpTransit Ceneri Base Tunnel (15.4 km), we show that suitable excavated materials can be used sustainably as a primary resource for tunnel concrete. This requires careful planning of the installations and storage areas by the client, timely building of the processing plants and other handling facilities outside the tunnel and a continuous evaluation of the raw material quality. 1. INTRODUCTION Spoil management is a central element of large construction projects. The systematic reuse of suitable excavated material not only saves natural resources, reduces transport distances and landfill volume, but can also decrease overall construction costs. Ideally, all of the concrete needed for tunnel lining can be produced with this on-site material. Such a natural resource management concept was applied for the construction of the new Gotthard Base Tunnel (L = 57 km). Spoil management concepts are, how-ever, difficult to implement and call for innovative techniques, sophisticated logistics and organization. In the context of large projects, environmentally friendly transport, processing and storage of millions of tons of excavated loose material represent another logistics challenge (Simmen & Lieb, 2010). This paper shows key factors that led to the successful completion of spoil management at the Ceneri Base Tunnel, which constitutes a part of the AlpTransit Gotthard Project (Figure 1)."

Jan 1, 2016

By Andrew J. Gaber

Beginning in 1961 the Coal Research Bureau of the West Virginia University School of Mines began a program of research to investigate the potential of the magnetic separation process to remove sulfur of the pyritic form from pulverized coal. Using a so-called isodynamic magnetic separator (1) it was demonstrated that significant quantities of pyritic sulfur could be removed from coal. Pulverized coal samples representing several different coal seams were individually screened into sizes in the 48 mesh by 200 mesh (297 to 74 microns) range, and untreated and steam-air treated samples of each were processed by the magnetic separator. The results of the investigations to magnetically remove pyrite from coal were published in two separate reports issued by the Coal Research Bureau (2,3), The isodynamic magnetic separator was designed about 30 years ago for use in geological and mineralogical laboratories (1,4,5) to isolate one or more minerals exhibiting only small differences in their magnetic propertiese Specifically, to accomplish this, the air gap of the unit was designed to provide a nearly constant magnetic gradient both laterally and longitudinally in the separating zone. It is reported that mineral concentrates of 99.5 percent purity can-be produced on closely-sized fractions after several cleanings through the unit. The isodynamic magnetic separator, therefore, was not expected to process coal containing sizes smaller than 200 mesh, or to demonstrate commercial capability to process pulverized coal. The primary purpose of the Coal Research Bureau in using the unit was that of determining if the magnetic process could remove pyrite from coal, and thereby encourage further research directed toward development of acceptable full-scale processing equipment.

Jan 1, 1969

By R. Michael Craig

The flood basalts of the Columbia Plateau in eastern Washington State are under investigation for suitability in siting a deep geologic repository for high-level radioactive waste. To support safety and feasibility evaluations of the proposed repository construction and operation, an assessment is necessary of the potential for inflow of groundwater to the repository excavations from the surrounding saturated rock. Preliminary estimates of inflow are presented using simple models appropriate to the current understanding of available data. Both normal and bounding analyses are presented.

Jan 1, 1986

By A. Aly Selirn

An economic simulation model was developed to predict the amount of copper recovered from copper oxide deposits and the cost of producing it as a function of the deposit parameters. The economic simulation model includes models of fragmentation design and cost, copper extraction, solution distribution and recovery, effluent solution cutoff grade, and financial analysis. Cost and price indices were also developed to evaluate the economic feasibility of in situ leaching operations as a function of their starting date. Application of the models to various properties having the same area and different ore thickness shows that the effluent solution cutoff grade does not vary with the ore thickness nor with its grade. The percent of copper recovery is, however, shown to increase with the increase in the ore thickness and is independent of the ore grade. it is also shown that while the profit per unit of extracted copper increases with the increase in ore grade or ore thickness, the rate of return on total investment does not show any correlation

Jan 1, 1977

By F. W. Bond

Predictive ground-water modeling is currently being applied to a wide range of engineering applications. In recent years models have been used to evaluate the effect of large ground-water withdrawals on regional water supplies; subsidence associated with overpumping; siting and design studies for chemical dumps; siting and safety aspects of nuclear waste storage; and heavy metal migration from disposal sites. Similar modeling techniques could be used to analyze water-related problems in the minerals industry such as mine dewatering (both open pit and underground), environmental and pollution control, and process water supply and disposal The objective of this discussion is to describe how ground-water models are being used to assist in the solution of water-related problems outside the industry and to extrapolate that use to mining problems.

Jan 1, 1980

By A. K. Sinha

Despite the tremendous efforts and costs incurred by the industry and regulatory agencies to prevent premature roof failures in underground mines, roof falls continue to occur frequently due to the very unpredictable geological conditions and dynamic nature of mining operations. In fact, roof falls continue to be the largest contributor to coal mine fatalities. The failure of a mine roof generally occurs following a prolonged, gradual degradation in its physical conditions. An electronic mine roof monitoring system has been developed and tested in operating mining sections. It monitors mine roof degradation on a continuous basis. The field test results are presented and discussed.

Jan 1, 1987

By Ali Ekrem Aritan

Exposure to hand-arm vibration (HAV) among the labor force in the mining industry can result in permanent vibration diseases such as behavioral disorders, visual impairment, osteoporosis, pain (mostly in the hands, wrists, and shoulders), circulatory system disorders, and malnutrition. In this study, the vibration exposure of excavator operators working regularly in 25 different natural stone quarries was measured. In addition, the relationship between vibration exposure and rock properties was investigated. Gloved and ungloved vibration measurements were performed and revealed that antivibration gloves reduce excavator operators’ vibration exposure by 7.10–25.95%. Samples from each quarry were characterized with rock mechanics tests. The correlations between the hand-arm vibration measurements and the natural stone physical–mechanical properties (uniaxial compressive strength, Shore hardness, Knoop hardness, apparent density and total porosity) were determined to be over 70%. One finding of the study was that the health risk in excavators cannot be reduced sufficiently by the sole use of antivibration gloves. Furthermore, the excavation of any rock with a Knoop hardness above 121 is associated with an 81% risk of HAV. To increase awareness of the danger of vibration exposure for natural stone miners, training programs should be provided, and technical and operational changes should be implemented.

By Charles L. Kimbell

Introduction Despite the focus on the so-called "high-tech" and service components of the economy, the minerals industry in 1987 continued to provide the world the overwhelmingly dominant share of the total raw material supply for all manufacturing operations. And, in the form of fertilizers and other soil treatment materials, minerals also supplied indispensable raw materials to ensure continued high production of the agricultural and forestry sectors of the world's economy. Moreover, the role of minerals as a source of construction raw materials was essential to that sector. On the basis of preliminary and partial statistics on world output of crude mineral commodities, 1987 appears to have been a year of further recovery from the recessional years of 1981-1983. The value of world crude mineral industry production (all mineral commodities including fuels) apparently advanced about 5% to nearly $1.1 trillion in terms of constant 1983 dollars.' That is significantly above the recently revised 1986 level of nearly $1.05 trillion, but still considerably below the record-to-date high of $1.27 trillion set in 1980, as shown in Table 1. That growth in value took place despite relatively flat world oil prices - oil being the most important component of the aggregate, as it has been for decades. There is insufficient information available to assess the total value of processed mineral commodities (refined metals, refined oil, manufactured fertilizers and the like). But a figure of $2.6 trillion (constant 1983 dollars) would be a quite conservative estimate for those materials derived only from primary or newly mined materials. And an additional, as-yet-unestimated increment should be added for processed materials derived from secondary raw materials - scrap and other reclaimed substances. From a world trade viewpoint, minerals and mineral products dominate in terms of tonnage. For example, in 1985, on a weight basis, mineral commodities including fuels constituted more than 58% of all goods moving through the Suez Canal and 53% of all goods passing through the Panama Canal. These waterways cannot accommodate giant tankers and ore carriers. So an even larger share of total oceanic trade is composed of minerals and mineral products. Yet, in terms of value, the share of the total accounted for by these industrial essentials is much lower than that accounted for by other commodities, most notably sophisticated high-tech equipment and other goods with a relatively high per-pound value. Worldwide data on the value of mineral export trade for 1987 is so incomplete at this writing that it is impossible to assess that actual level. Indeed, the compilation of similar available data for 1986 covers only the exports of nations with developed market economies. In 1985, these countries accounted for only 67% of total world exports of all goods. They accounted for only 41% of world exports of major mineral commodities: crude nonmetals; metal ores, concentrates, and scrap; mineral fuels; nonferrous metals excluding gold; and iron and steel. For these developed-market-economy countries, the value of exports of these major mineral commodities declined by more than 10% between 1985 and 1986. Most of the shortfall came as a result of a 26% drop in the value of fuels exports. If these patterns of

Jan 7, 1988

By Harrison A. Schmitt

During .the past five decades or so we have passed from a time when it was difficult to point to a mine or an ore body and verify that it had been discovered by geological methods, through the. Twenties when the common saying was, "Who ever heard of a mine found by a geologist?", to recent decades when hundreds of mines and ore bodies are acknowledged geological discoveries and the above query can be ignored. Recently, however, the application of mining geology appears to have been downgraded, or so it seems to me. Basic geology in mining has been cheapened and glossed over in favor of geophysics and outcrop sampling, even though the latter is merely one technique of mining geology and, to some extent anyhow, has been used for a. long time. (Locke, 3, pp 81-87). Geophysics by itself and in conjunction with geology has had success in certain geological provinces, but limited attainment in mountainous terrane except in those few cases where strongly magnetic minerals are associated with ore. Nevertheless, in the Cordillera .many experimental techniques are offered as proved ones. This is not an intent to try to depreciate honest geo- physics. Continued experimentation and use of it is approved by all, but at the same time it is foolhardy to throw mining geology overboard, Generally both approaches should be considered and usually, at first anyhow, geology is the most direct one.

Jan 1, 1960

By Ed L. Schrader

Kaolin of the Georgia-south Carolina "Clay Belt" are used in a wide variety of filler and extender applications. Sane applications specifically require the performance enhancement delivered by incorporating kaolin into the product formulations. Other applications are less specific in requirements for an inert mineral filler. In order to be a feasible candidate for filling and extending, a mineral or mineral product must be generally inert (except where specific interaction with the filled medium is desired), inexpensive, easily handled and transported in a variety of forms, accessible to a broad segment of the desired market, and must exist in sufficiently large ore reserves as to assure production for many years. Of course, more precise requirements are necessary in specific applications of a prospective filler material.

Jan 1, 1985

By M. Karmis

Subsidence planning and control must be an integral part of mine design in order to minimize the economic impact of underground mining on the surface. Pre-calculation of surface deformations which may cause damage to surface structures must be performed and dam-age criteria must be established, if the response of structures to such movements is to be determined and the extent of damages to be assessed. In this paper the Surface Deformation Prediction System (S.D.P.S.), which can be used to predict accurately the vertical and horizontal parameters of surface movements due to underground mining, is discussed. The Subsidence Response Modeling Program (S.R.M.P.). which can be applied to evaluate the response of buildings to subsidence-induced movements, is also reviewed. Finally, an example is presented demonstrating the applicability of these techniques for subsidence design and control.

Jan 1, 1990

By Walter E. Kramer

The advantages derived from the use of pellet burdens in blast furnaces are so great, that hematite ores are being converted into pellets in greater quantities each year. The conversion of these ores into pellets appears on the surface to be relatively simple. In reality, this is not so. Serious difficulties are encountered in drying these pellets that do not exist in the drying of taconite concentrate pellets. The ores that present problems are goethite and earthy hematites. Green pellets prepared from these ores have very law shock temperatures, 200-600° F. The shock temperature of a green pellet according to our definition is the highest initial temperature to which a green pellet may be exposed without suffering decrepitation. Decrepitation may involve spalling, fracturing or total disintegration. The poor shock properties of these green pellets result from the inability of the vaporized water to escape freely and easily as it is formed with¬out affecting the integrity of the pellet. As a consequence, the pellets must be carefully dried prior to induration. This careful treatment is costly. The slow drying process restricts productivity and requires larger furnaces than desired. The use of an additive to elevate the shock temperature of the green pellets would increase productivity. Bentonite is used in some pellet plants to improve balling but it raises the shock temperature only slightly. Nalco became interested in the shock temperature problem because of its activity in the development of organic pelletizing aids for taconite concentrates. The findings reported here are an outgrowth of our experimental work on the development of shock temperature additives.

Jan 1, 1967

By James J. Broderick

In the production of Pig Iron - Limestone, Coke and Iron Ore pellets are changed to the blast furnace and reacted at approximately 2,800 degrees F. The resultant products are molten iron and a molten slag - not unlike lava. The molten slag stream is channeled into open pits, cooled with water, crushed and sized for various industrial applications. The production of steel from pig iron in open hearth, B0P, BOF and electric furnaces results in somewhat similar slags: but since free lime is normally the flux, the resultant slags are not satisfactory for use in cement pastes. When exposed to water, the lime slakes, expands by 250% and ruptures the concrete. Thus, the slag discussed first is Blast Furnace Slag composed of 30 to 40% Silica (SiO2) Alumina (AL202) 7 to 16% Lime (CaO) 32 to 45% and Magnesia (MgO) 5 to 15%. The oxides do not exist as free oxides but rather as silicates and alumino silicates which are chemicall inert. Since transportation costs limit the area of use, blast furnace slag can only be found in concrete products produced within 60 to 100 miles of a blast furnace operation. Even within these areas where slag is in heavy supply, quite often the use of slag is minimal for concrete aggregate and the major outlet is road base.

Jan 1, 1985

By Ross W. Smith

Many studies have been made of the microflotation of quartz (1,2,3,4,5,6) and alumina (3,5,6, 7,8) using various anionic and cationic hetero- polar hydrocarbon surfactants as collectors. A few studies have been made on these minerals using amphoteric hydrocarbon collectors ( 9,10, 11,12) and only a few studies have been made on the use of fluorocarbon surfactants as flotation collectors (13,14). The present investigation compares microflotation response of the two minerals in hydocarbon and fluorocarbon collector systems of the anionic, cationic and amphoteric types. An attempt is made to relate flotation response of the minerals to their electrokinetic behavior and the pKa values of the collectors.

Jan 1, 1979

By Richard J. Wilson

The importance of coal as a major source of energy used by the steel industry has been increasing due to the gradual changeover from steel- making by the open hearth process to steelmaking by the basic oxygen process. Since the production of steel by the BOF process increases the demand for hot metal, there is a growing need to ensure the supply of coke required for the production of hot metal. Coal used for cokemaking has become, therefore, an increasingly important raw material for the steel industry in recent years. Our current projections indicate that coal will be the source of 71% of the total energy requirements of Inland Steel Company in 1985. As a result of the energy shortages of the last few years, various conservation programs have been initiated by the steel industry to reduce the consumption rate of fuel. The efforts to conserve energy have been successful to a great extent due to the rapid advances made in the technology of ironmaking that facilitated gradual reductions in the quantity of coke used per ton of hot metal produced in the blast furnaces. The decrease in the consumption rate of coke was made possible by the use of improved raw materials, such as iron ore pellets and fluxed agglomerates, the operation with high blast temperatures, the injection of auxiliary fuels, and the enrichment of the blast with oxygen. It is expected that additional reductions in the fuel consumption rate will be possible in the ironmaking operations of the large blast furnaces that are being equipped with facilities for proper burden distribution and for operation with higher blast temperatures at high top pressure. The purpose of this paper is to show the effects of coke quality on the production of BOF steel. The importance of coke quality will be pointed out by discussing the effects of the physical strength of coke on both the blast furnace productivity and the steelmaking operations of an integrated steel plant, such as Inland Stee1 Company.

Jan 1, 1980

By Frank F. Rahne

Butler Taconite, operated by the Hanna Mining Company, is an Iron ore pelletizing operation that is located on the Western end of the Mesabi Iron Range in Northeastern Minnesota. The operation mines low-grade taconite ore and through primary crushing, two stage grinding, magnetic separation, agglomerating and indurating, produces 2.6 million annual tons of high quality, 66% iron pellets. Mining and stripping is done with 13 - M100 trucks and 5 - 12 cu. yd. shovels. The operating processes in the concentrator and pellet plant are primarily con¬trolled through a centralized control room and monitored by a PDP l140 computer. During 1969 and 1970, a re-organization of the Company took place. Through this re-organization, each mine unit was analyzed and studied to determine the proper staffing of the internal departments. At this time, it was decided to continue with further detailed studies of the Maintenance Department with the intent to reduce maintenance costs. Maintenance costs at the time of the re-organization were 38.6% of the total mine operating cost. The preliminary study indicated that the Maintenance Department had a system of maintenance, as a matter of fact, it had a separate system in each sub-maintenance division and in some of the sub-divisions each foreman had a system of his own. Therefore, from the data collected, it was decided to develop one system of maintenance that could be utilized throughout the entire operation. To determine the type of system suitable to all phases of the operation, detailed time and method studies were conducted. All types of maintenance tasks performed at the operation were studied. The data collected was analyzed and the recommended improved methods were reviewed with the Maintenance Superintendent and his staff. The new improved methods that were accepted as feasible, were introduced into the system immediately.

Jan 1, 1975

By Hemendra N. Kalia

The target to double the coal production by 1995 presents a formidable challenge to the coal mining industry. The mines of future, probably will be located in relatively difficult geological environment because of the exhaustion of the well defined bedded and easily minable deposits. To compound the problems of mining industry will be the reliance of power plants need for coal. The coal must reach the power plants on schedule to avoid expensive blackouts and brown¬outs. It will be imperative that the mines operate without interruptions and at designed capacities. The parameters which have been traditionally responsible for the interrup¬tions of production are: breakdown of production machinery, labor management relations and geological anomalies. Of these three problems, solutions for the first two can be arrived at by developing procedures to correct the situation. A planned maintenance and preventive maintenance program will go a long way in minimizing the equipment breakdowns. Labor relations will eventually improve as the miners begin to enjoy long-term employment. However, with the geological problems, the situation will probably continue to deteriorate and would require careful planning to minimize the impact of geological problems on production and safety. Some of the geological aspects which interfere with production are: faults, washouts, slips and slickensides, water bearing overlying strata, impuri¬ties in the coal seam, and presence of expansive clays in the coal floor. The design of large capacity mines will have to incorporate the geological distur¬bances and mine through them it may become very uneconomical to abandon producing sections because of the presence of the geological anomalies. This paper discus¬ses the geological aspects of coal mining which should receive consideration from the inception of the mining ventures. Pertinent geological aspects are discussed to develop the data base which will aid in evolving safe and efficient mine layouts.

Jan 1, 1976

By J. P. Rider

The number of extended cut mining systems has increased significantly in coal mines over the last decade, and there is a constant push to extend the face ventilation systems to even greater setback distances. The need to maintain airflow at setback distances of12.2 m (40 ft) and beyond requires that methods for delivering intake air to the face be improved, or alternative ventilation techniques be implemented. The emphasis of this research effort was to examine various techniques to improve the distribution of available air at the mining face in order to reduce face methane levels. A study was conducted comparing the performance of a jet fan, used in conjunction with a machine mounted scrubber, with blowing curtain ventilation in a 27.5 m (90 ft) heading. In addition, a second study was performed on blowing curtain systems examining how scrubber flow, intake air velocity, and curtain setback influence face methane concentrations. Results showed that when the heading advances to a depth of 27.5 m (90 ft) blowing curtain systems were more efficient at diluting face methane levels when compared to a jet fan. Also, increases in scrubber flows and curtain velocity resulted in lower face methane concentrations for blowing curtain systems at 9.2 and 15.2 m (30 and 50 ft) setbacks.

Jan 1, 1997

By John M. Karpinski

A method and equipment have been developed Tor measuring the impact strength of grains of brittle materials. It is shown that brittle materials develop a characteristic particle size distribution when fractured by impact. A simple mathematical model has been found to describe this distribution, and one of the parameters of the model has been designated the r value. The r value is directly proportional .to impact energy and, for fixed impact energy, it becomes a useful criterion of grain strength. Data are presented on the variation of the r value as a function of sample history, initial size, energy input and number of impacts, The results are interpreted in terms of the flaw theory of brittle fracture.

Jan 1, 1964