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By C. L. Karr

Establishing suitable control of pH, a requirement in a number of mineral and chemical industries, poses a difficult problem because of inherent nonlinearities and frequently changing process dynamics. Researchers at the U.S. Bureau of Mines have developed a technique for effectively controlling such systems. This technique successfully combines the process control capabilities of fuzzy logic and the search capabilities of genetic algorithms. Fuzzy logic offers an effective mechanism for handling nonlinearities, while genetic algorithms can provide fuzzy logic controllers with real-time adaptive capabilities. This Bureau-developed technique is applied to a laboratory acid-base neutralization experiment. Nonlinearities in the laboratory system are associated with the logarithmic pH scale and the changing process dynamics are due to alterations in pH and buffering capacity input solutions. Results indicate fuzzy logic controllers augmented with genetic algorithms offer a powerful alternative to conventional process control techniques in such nonlinear, rapidly changing systems.

Jan 1, 1992

By R. J. Kolada

The ventilation systems of coal storage silos are normally capable of rapidly dispersing any accumulations of methane in the atmosphere above the coal pile surface. However, the results of an investigation which is presented in this report show that hazardous concentrations of methane can accumulate within the coal pile. Methane trapped within the coal pile is released into the atmosphere of the loading gallery when coal is discharged from a silo. If the methane released is of a flammable concentration it is necessary to ventilate the gallery to reduce the risk of an ignition. This report proposes a simple test, which, after further investigations may prove to be an effective method to calculate gallery ventilation requirements.

Jan 1, 1985

The current understanding of the mechanics of rock fracturing during smooth blasting is largely empirical and qualitative due to an inability to model the dynamic process at the fundamental level. In order to overcome this difficulty, a numerical simulation of smooth blasting is performed using the Dynamic Lattice Network Model. This model is capable of simulating material inhomogeneities and the dynamic evolution of fragmentation at the micromechanical level. In this study, smooth blasting techniques are numerically analyzed to characterize the development of the damage rock zone during explosive fracturing.

Jan 1, 1995

By S. M. Moore

Each year more than 400 coal miners are injured (fatal and non-fatal) by rock falling from between or around roof supports. Many of these injuries could be prevented by the installation of roof screen (wire mesh). However, many coal mines may be reluctant to use roof screen because of the added cost. The goal of this study was to determine the potential saving in workers? compensation (WC) premiums that could be achieved due to a reduction in rock fall injuries after roof screening. The WC rate-setting methods utilized by IL and KY were investigated in this study. Using actual data obtained from MSHA, national and state WC bodies and individual insurance companies (e.g. average cost per injury, loss cost rate, number of injuries per year, number of injuries preventable each year with roof screening), hypothetical mines (representing two mine sizes: 67 and 150 employees) were constructed with realistic ranges for estimates of injuries and WC premium costs. Using each state?s actual WC rate-setting formulas, total savings in WC costs after a three-year period were determined. Across both states, savings in WC premiums ranged from 1.8% to 14.6% when injuries were reduced by 10% to 20%. Additionally, an economic analysis was performed for an existing mine consisting of 67 employees. For this mine, the annual cost of a roof screening program was estimated at $240,000. If the screening prevented 13 ?struck by? WC claims over a 3-year period at this mine, the reduction in WC premiums alone could pay for the entire screening program.

Jan 1, 2010

By M. K. Mohanty, H. Akbari, L. A. Ackah

Dry separation was the predominant method of coal cleaning in the United States from the 1930s to 1980s. The application peak of dry separators for cleaning raw coal was in 1965, when about 23.1 Mt of cleaned bituminous coal was produced. The main advantage of dry coal cleaning is the elimination RIWKH GHZDWHULQJ VWDJHV DQG VLJQL¿FDQWO\ UHGXFHG moisture in comparison to wet processing. In addition, developed dust control systems have made dry cleaning method an environmentally friendly process. The largest air-based coal cleaning plant was built in Pennsylvania in 1968 and could clean 1,272 t/h of raw coal sized smaller than 19 mm. This was followed by a decline in dry coal cleaning to less than 3.6 Mt in 1988. Some of the main reasons that shifted coal operations IURPGU\WRZHWSURFHVVLQJZHUHWKHQHHGIRUPRUHHI¿FLHQW separations with lower density cuts, increase in raw coal surIDFHPRLVWXUHVSHFL¿FDOO\LQXQGHUJURXQGPLQLQJWRFRQWURO GXVW ¿QHUSDUWLFOHVL]HUHTXLUHPHQWV LQFUHDVHLQ¿QHVLQUDZ coal from underground mines, and health and safety concerns related to dust and noise (Arnold, Hervol and Leonard III, 1991; Miller, 2011).

By I. R. M. Chaston

Abstract. This paper puts forward the concept of 'radial' plant layout where all crushing, milling and treatment operations are preferably concentrated in one central area and these separate stages are connected by radiating conveyors to and from outside storage areas. This system is contrasted to the more customary system of 'linear' plant layout where the crushing, milling and often the treatment operations follow one after the other in separate buildings. The radial system simplifies and improves contral and supervision to a very considerable extent and can lead to a form of continuous plant operation with the separate sectors shutting down in succession for necessary maintenance while maintaining the overall plant operation. The paper is illustrated with example: from past and recent diamond treatment plant practice in South Africa which demonstrate the reduction in plant labour achieved by this system. Previous objection to this type of layout on the grounds that it inhibited plant expansion are shown to be unwarranted. Radial Layout for Increased Treatment Plant Productivity A great deal of time and trouble is spent by highly qualified and experience( metallurgists in developing the right treatment process for a given ore. This process is then often expressed in a treatment flowsheet of the type shown in Fig. 1 which shows a typical diamond plant. This flowsheet, when completed, is commonly handed over to the mechanical engineers who then design the layout of the equipment indicated on the flowsheet and produce the working drawings upon which the detailed construction of the treatment plant will be based. It is an unfortunate fact that the tedious and time-consuming juggling of equipment and inter-plant transportation is often left to hard-working draughtsmen who, however capable' in their field, lack practical experience in the day-to-day operation and maintenance of the treatment plants they design. As a result many plants have been produced which, while they satisfy the requirements of the flowsheet with minimum capital requirements, cost far more than should be necessary to op¬erate and maintain. It is often possible to change individual items of equipment which do not achieve the performance required of them, but it is usually extremely expensive to change the basic layout of the plant if this should be found to be unsatisfactory. It should therefore be recognised that great care and attention should be spent on consideration of the basic layout of any treatment plant and that the views of both designers and operators should be fully regarded before settling upon the inevitable compromise dictated by the varying requirements of process-engineering and economics. It is unfortunate that this important subject receives such scant regard in the standard ore dressing text books and hand-books, being usually dismissed in a few paragraphs.

Jan 1, 1977

By Andrzej M. Wala

A knowledge of the friction factor (K-factor) is necessary in planning and designing mine ventilation systems for least cost and highest effectiveness. The friction factor used must be accurate and reliable for correct estimation of airway resistances. At present, the friction factors are determined by using tables of published values. These values were established principally for metal-mine openings having small effective areas. This presents a problem to the ventilation design engineer whose responsibilities center around the design of effective ventilation systems for large room-and- pillar mechanized underground coal mines. Friction factors selected from these tables could be excessively conservative for large scale room-and- pillar operations. With only limited data on the K-factor (which are considerably site dependent) for Kentucky's coal mines and for all the above mentioned reasons, it was concluded that there is a need for field investigations to determine these values in-situ for existing mining conditions in Kentucky. The author describe the study carried out in ten coal mines located in eastern and western Kentucky and present the results of the investigation in both tabular and graphical form.

Jan 1, 1991

By E. O. Jacobs

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

Feb 23, 2014

By U. Schoepf

Economic and at the same time environmentally acceptable mining of small vertical ore bodies and veins to great depths has always been a challenge for miners. The Bauer cutter system, widely used in civil engineering, has been further developed for applications in exploration and mining, to a sustainable system for selective mining with a focus on small vertical ore bodies and veins, as well as residual ore in open pit operations. Current situation of conventional mining of small ore bodies and vertical veins Small ore bodies and vertical or near-vertical ore veins often pose a challenge to the mining industry. The relatively small size of the ore deposit over great depths or lengths, with only limited exposure to the surface makes economical mining difficult. Open pit mining of such ore bodies must either be terminated early because of the high stripping ratio and the enormous environmental impact or is unprofitable from the very beginning. The required massive stripping of waste rock leads to high material hauling times and costs, intensive roadway and bench construction and maintenance, possible safety hazards due to heavy vehicle movement, pit wall stability risks, intensive surface water management and massive waste dump requirements. In addition, it can be assumed that increasingly extensive rehabilitation measures will be required in the future after mine closure. Particularly in vertically oriented magmatic and hydrothermal deposits the technical, economic and environmental limits for further pushbacks, to extend the open pit depth, can lead to an early end of mine life even if a significant quantity of residual ore is left behind. Going underground is only a viable option in a limited number of mines with very high ore values and volumes. The high development cost of an underground mine, as well as the higher underground mining costs, often prevent further mining to greater depths.

Feb 1, 2023

By S. K. Kawatra, S. J. Ripke

During iron ore pellet production, bentonite clay is used as a binder. Typical pellet plants spend from $3 million to $5 million annually for the clay. If bentonite dosages could be reduced by using it more efficiently, a significant cost savings would result. If the binding mechanisms can be completely understood, procedures can be developed to use bentonite more efficiently. Classical bentonite bonding theory is based on the behavior of bentonite at low percent solids and high mixing shear rates. Under these conditions, bentonite was understood to expand, disperse into platelets, and dry into a bonding "film" or "gel." However, these are not the conditions that exist during pelletization, which is carried out at high percent solids and relatively low shear rates. In this paper SEM imaging was used to identify and explain the bonding mechanisms of bentonite on the surface of magnetite concentrate. It was determined that bentonite would form a fibrous network under the proper conditions and that the formation of these fibers corresponded with an increase in the bonding of particles by the bentonite.

Jan 1, 2000

Water contact angles in the air/water/francolite, fuel oil/water/francolite and fuel oil/water/quartz systems were measured to describe the wetting characteristics of these minerals. It was found that white francolite is more hydrophilic than black and tan francolite both in the absence and presence of fatty acid addition. The contact angle measurement results do not correlate very well with the flotation response and it appears that kinetic aspects of the bubble attachment process play an important role in the francolite-fatty acid flotation system.

Jan 1, 1997

By Brian Ulrich

The majority of individuals involved in the mining industry can appreciate and under-stand that mining is an activity that is necessary to satisfy the very basic needs of society, and to assist in accommodating our ever-changing world. As the expression goes, ?if it can?t be grown, it has to be mined.? And at this point in time, society has granted the mining industry the right to go about the business of mining, with the general anticipation that the work will be carried out without causing undue harm to the environment or populations in and around the mining operation. The term ?sustainable development? is gaining momentum as a popular concept, and indeed it has become something of a catch-all phrase, but it is important that the idea behind the term is not cast aside as a nonsense buzz word, as it simply is an indication that development (e.g. mining) can be satisfactorily carried out with an eye toward stewardship of the environment and society. On Feb. 19, 2010, a round-table discussion (Roundtable 2010) on ?Strides Toward Sustainability in Mining? was hosted by Knight Piésold and Co. (Knight Piésold) at the Red Lion Inn and Casino in Elko, NV. Knight Piésold had local representatives (Bryan Ulrich and Steve Boyce), as well as representatives from other office locations (Cynthia Parnow and Rick Damiani from Denver, CO, and Rick Frechette from Tucson, AZ) to help facilitate the discussion. The meeting played host to 30 attendees from five states. Attendees included personnel from nine mining properties and various corporate offices. The majority of participants were people who are directly involved with environmental work on a day-to-day basis. Others were project managers whose jobs involve some level of environmental focus.

Jan 1, 2010

Mine design and selection of ore processing capacity depend upon a correct estimate of the grade-tonnage distribution. The estimate must reflect what can be recovered and processed. The McCoy/Cove operation in central Nevada, USA, is a gold and silver mine. Case studies of recoverable reserve estimation for gold and silver were made using multiple indicator kriging and the log-affine variance correction. From this model, the grade-tonnage distribution was constructed. Optimal pits were generated by utilizing the distribution, and the results were compared with the pit generated by ordinary kriging. Studies indicate that the proposed method for multi-metal recoverable reserve estimation is more accurate than ordinary kriging in terms of both tons and the grade. Using recoverable reserves for mine design will maximize global recovery of mineral resources.

Jan 1, 1997

By J. T. YIi-Penttiia

Dust formation and reaction mechanisms of copper matte particles were investigated in simulated flash oxidation conditions. The granulated and ground matte consisted of 72 wt% Cu, 4 wt% Fe and 21 wt% S. Experiments were conducted by using a laminar-flow furnace with a reaction gas composition ranging from 20 vol% to 75 vol% O2 in nitrogen. The particle feeding was carried out by the single-particle method and samples were quenched after a specified reaction time (approximately 0.05-004 s) in a cold water film. Experimental temperatures were between 800 and 1300°C. Chemical analysis was used to determine oxidation degree, and an optical and scanning electron microscope combined with energy dispersive analysis was used for characterization of the reacted particles.

Jan 1, 1998

By M. B. Haggerty, R. J. Sheets, F. Abbasy

To address coal refuse tailings storage needs for a mine operation in western Canada, a feasible solution was to convert excavated open pits into tailings cells. A slope stability investigation and design study were completed to determine the necessary width and slope geometry for in-situ native plugs as the impoundment embankment. The native plugs separate the previous open pit from the current active open pit. This configuration allows for the deposition of refuse tailings in the previous pit while allowing mining to safely continue “downstream” of the temporary impoundment. As mining progresses, each subsequent pit will be filled with refuse tailings; thereby, buttressing the upstream slope of the previous native plug. Although these cells are excavated, and the timeframe for downstream exposure is relatively limited, the native plugs are classified as dams and must be designed to meet applicable safety of dam standards since they impound water and tails above mining personnel in the subsequent open pit. The presentation and paper will discuss the investigation and analysis conducted to develop the geotechnical and hydrogeological design recommendations.

Mar 2, 2022

By N. B. Prenn

Many recent projects have been developed and mined based upon imaginary reserves. Imaginary or "geo-fantasy" reserves have cost many companies millions of dollars. The significant and varied technological advances in the mining arena have done little to curb reserve calculation problems. These advances may have served to increase the prevalence of reserve problems by putting more tools in the hands of personnel not properly trained or experienced in reserve estimation. This paper will discuss potential problems related to calculating reserves, which include: SAMPLING ERRORS -obtaining a representative sample. -Decay analysis of wet RC drilling -Bias introduced by sample preparation. -Assay bias; Coarse gold. -Specific gravity samples. GEOLOGICAL ERRORS -structural boundary definition. -Separation of high grade and low grade zones. -Incorrect continuity assumptions MODELING ERRORS -Too much influence of high grade samples. -Improper method of calculation. -Assumed range of influence. -Errors in the data. ENGINEERING ERRORS -Inaccurate assumptions. -Inadequate metallurgical testing. -Designed bottlenecks.

Jan 1, 1992

Anomalous geologic or stress conditions ahead of the longwall face can cause great harm to both the individual miner and the mining operation as a whole. The U.S. Bureau of Mines has been developing seismic tomography techniques to image the panel ahead of the face. This paper presents the results of a field effort in which a 60-m (200-ft) segment of a longwall panel containing a fault zone was surveyed daily as the face approached. Stress distribution, geologic structure, and dynamic elastic properties within the panel were plotted and compared to static laboratory measurements. The surveys successfully imaged an anomalous stress concentration, likely influenced by the presence of the fault zone. The calculated dynamic physical properties generally agreed with laboratory measurements.

Jan 1, 1995

By Ronald H. Mullennex

The growing need for development of thinner, more erratic, or less easily- mined coals in the Appalachian region requires more detailed analysis of conditions and factors controlling or influencing deposition of these seams. The value of depositional modelling in evaluation of such coals has been demonstrated in many recent studies and publications. Such modelling may be applied to allow prediction of factors varying from regional coal occurrence trends to very local areas of seam discontinuities, but requires thorough utilization of all available types of data. Mapping of general depositional energies, as derived from basic geophysical and driller's logs, can be applied to specific prediction of coal occurrence, and projection of particular facies as representative of unique depositional features or conditions often proves more applicable to coal character delineation than does mapping of the coal itself. Depositional modelling and trend projection may also serve as a guideline in reserve classification and confidence-levels in reserve estimations.

Jan 1, 1981

By F. M. Benavides

This paper presents recent developments in federal environmental regulations, which in the view of the author, affect mining and the mineral processing industries. This is a summary of activities by the administration, congress and regulatory agencies during 1990. The information presented is a recap from material published. The emphasis is given to Air Quality regulations, although other environmental concerns are reviewed.

Jan 1, 1991

By S. J. Schatzel, J. D. Addis, V. Gangrade, L. L. Chasko, C. A. Hollerich

"A ventilation study using tracer gas was conducted at a western US coal mine. The objective of the study was to evaluate the movement of longwall face air exchanges between the face and worked-out area and to document the presence or absence of face airflow pathways between these locations. The mine operator uses a bleederless longwall ventilation system with a back return and a blowing mine ventilation system. The study was conducted on an active panel and included both underground and surface monitoring sites. The study used sulfur hexafluoride (SF6) released as a slug on the longwall face and in the front of the gob inby the face. The velocity of the tracer gas movement in the gob was 0.019 m/s (3.7 fpm). The rate of movement for the overall tracer gas slug averaged about 0.0091 m/s (1.8 fpm). A separate tracer gas test initiated with the release of SF6 into the legs of the first shield showed the existence of more than one pathway of face air in the general direction from the headgate towards the tailgate corner. Maintaining adequate ventilation air on longwall faces is important for worker safety and for the dilution of methane emitted from the face and caved gob. A more detailed characterization of longwall system air and gas movement allows a mine to better assess its ventilation design for controlling gas on the face and in the gob. INTRODUCTION During a series of stakeholder meetings, a near unanimous concern was expressed related to maintenance of effective ventilation airflow on longwall faces. There was a strong interest expressed regarding the impacts of face length and caving characteristics on the ability to maintain adequate face airflow levels. This study seeks to understand and improve a mine operator’s ability to monitor and control ventilation and methane concentrations across the longwall face by assessing airflow variations in terms of roof caving characteristics and face length. National Institute for Occupational Safety and Health (NIOSH) researchers seek to identify flow paths of ventilation airflow on longwall panels with variations in roof caving characteristics and longwall face lengths. The project research aims to develop an understanding of the role of gas dynamics in variable broken rock, interactions with ventilation airflow and methane concentrations across the longwall face area. The research also addresses continuous ventilation monitoring along the shield line to provide early detection of gas exchanges between face and gob, and thus improve a mine operator’s ability to monitor and control ventilation and methane concentrations around the face. In the context of this paper, the longwall gob refers to the pillared area behind the shields. This work reports on results from one project task to conduct field based research using a tracer gas to describe face air and gob area gas movement in a bleederless longwall ventilation system that incorporated a back return."

Jan 1, 2017