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By Pradhan GK

Blasting is one of the most important operations involved in surface coal mining. The removal of over-burden waste in surface coal mines of India had experienced many improvements in terms of blasting, explosives selection, blast design, equipment selection, deployment. etc. Two case studies of very large surface coal mines have particular importance in their blasting operations. Both these units have been equipped with large capacity excavating machines, hauling units and also have some difficult mining situations. Blasting is done in benches in close proximity to human dwellings and over coal seams developed by underground methods with problems of high wall stability etc, as well. The various steps taken to improve the blasting operations ensure smooth operation of the equipment to meet the targetted coal production.

Jan 1, 1991

By Scott Giltner, Allan Koski

Blasting is one of the lowest cost yet most critical parts of the mining cycle. This paper discusses the findings of an audit conducted on the blasting operation at an iron ore mine. The purpose of the audit was to review current blasting practices in order to identify opportunities for production/cost improvements. The approach taken in the audit was to observe general blasting practices, their related downstream effects and to compare current procedures to established best practices.

Jan 1, 2009

By Stephan Mulch, Christian His, Patrick M. Stephan, Thibault Champion

"When fuel costs increase dramatically, waste to energy (WTE) conversion technologies become a good alternative to produce energy. The potential energy available in domestic wastes, in developed countries, could be upwards of 4% of their total energy needs. Due to low energy recovery and low level of treated domestic wastes in many countries, the energy coming from waste is generally less than 0.5% of the country needs.Domestic waste incineration can convert heat to electricity for industry and housing and allow waste volume reduction in countries where land fills are a scarce resource.There is a request to improve existing combustion technology by increasing energy recovery with better heat transfer in the boiler and also by increasing lining durability with more resistant materials and technologies.The knowledge of corrosion phenomena and material performance allows Saint-Gobain Group to develop and propose high performance refractory lining solutions.IntroductionThe interest in alternative energy has been growing dramatically in the two last decades due to several combined factors, such as global energy demand, fuels prices evolution (e.g. crude oil, Figure 1) or environmental and geopolitics factors"

Jan 1, 2008

By Kelvin K. Wu

A coal waste disposal dam failed on Buffalo Creek near Saunders, West Virginia, on February 26, 1972. This accident resulted in the loss of 125 lives, left over 4000 people homeless, and resulted in millions of dollars in damage to several downstream communities. As a result of this tragic event, major changes occurred in the mine waste disposal practices used by the U.S. coal industry. This paper summarizes changes in U.S. coal-waste disposal practices in the nearly 35 years since the Buffalo Creek dam failure and identifies safety issues that need to be addressed for continued improvement. While many organizations and individuals have played roles in the improvements that have occurred, this paper focuses on the role played by MSHA and its predecessor agencies.

Jan 1, 2006

By Donald G. Foot, Jeffrey D. Mckay

Flotation columns have been readily accepted for use in most sulfide flotation plants: however, recently columns are being used in many other areas. Recent improvements in design methodologies have overcome many operating problems and led to improvements in metallurgy. In addition. Physical improvements in column design have simplified their operation while leading to better control. The Turbo-Air External Bubble Generator has provided a method for bubble size control and variation in air holdup and carrying capacity. These have enabled commercial operations to improve grades and recoveries by optimizing performance.

Jan 1, 1989

By David Estrella, Hector M. Lizama, Jhonny Carrión

"Microcel™ sparging systems were installed on one column of the molybdenum cleaner circuit and one column of the copper first cleaner circuit at Antamina. The Microcel™ system is known to generate finer bubbles than jetting-type spargers, and smaller bubbles have been associated with higher recoveries in flotation. Alternating tests were carried out on the molybdenum column, using either jetting-type spargers or the Microcel™ system. Experimental conditions of gas flow rate, wash water rate, and froth depth were tested. Use of Microcel™ decreased the bubble sizes from 2.6-2.9 mm to 1.5-2.0 mm. In addition, Microcel™ improved both unit molybdenum recovery and unit molybdenum concentrate grade. In the copper first cleaner circuit, side by side tests were carried out that compared the Microcel™ column with a parallel columns fitted with jetting-type spargers. Best results were obtained at manifold pressures of 260-290 kPa, where bubble sizes of 1.6-2.6 mm were observed. In either copper or molybdenum flotation, the Microcel™ system required only 50-60% of the gas flow used by jetting-type spargers.INTRODUCTIONAntamina is a copper-zinc mine located in the Peruvian Andes. Compañía Minera Antamina is owned by BHP Billiton (33.75%), Xstrata (33.75%), Teck Cominco (22.5%), and Mitsubishi (10%). The mine was commissioned in 2001 with a capital investment of US$2.3 billion, and has a nominal 100,000 t/d mill capacity. Mining, milling, flotation, and tailings impoundment take place at the mine site, which sits at an altitude of 4,300 m above sea level. The deposit is a polymetallic skarn ore body with intrusive phases of quartz-monzonite porphyry into Cretaceous aged limestone [Evans et al, 2005]. Ore body thickness is 100 to 150 m and has the shape of a flat-lying crescent. Copper is present mainly as chalcopyrite with a minor bornite component. Zinc is present as sphalerite. Molybdenum is present as molybdenite. Some lead, bismuth, and silver are associated with the sulphides. The deposit is currently classified into six main ore types [Dechert, 2006], grouped into two categories: copper and copper-zinc. The mill produces four concentrate types: copper, molybdenum, zinc, and lead-bismuth. Copper, zinc, and lead-bismuth concentrates are transported by pipeline down to the port of Huarmey. Molybdenum concentrates are bagged and trucked to port."

Jan 1, 2008

By William L. Barnes, Maurice Leiser

INTRODUCTION The literature on project management considerations and techniques for large rail rapid transit projects in mid-1979 was fairly large and getting larger. UMTA was establishing special organizational elements to deal with the subject as it related to those properties requesting capital assistance, and comprehensive project management plans were being requested from those properties as an early step to build confidence in UMTA that the particular project could be planned, designed, and executed efficiently and effectively, thereby using critically short capital assistance funds to best advantage. In the late 60's and early 70's, the choices of models for heavy rail construction would have been quite limited.., and perhaps much simpler than was the case in 1979. One of the writers was with an agency in 1979 in the process of finalizing its organization for project implementation after several years of study and had the opportunity to review the experiences of others at length, presumably to build on the success and to try to avoid the pitfalls and failures. The properties that were surveyed all reported more or less success stories. One could only conclude that there are many ways to organize for a major transit (construction) project and that there is a great variety of viable management structures, but it seemed that chances for success were best where the executing property had prepared a comprehensive project management plan, then resolved to follow it. Perhaps more important, a commitment or prior approval had been sought from UMTA as to the validity of the project management plan, and the property was allowed to proceed without detailed prior UMTA review or approval of all specific intermediate steps. Most important, however, an early overall UMTA funding commitment had been obtained that permitted some reasonable expectation of the rate of funding, perhaps by commitment

Jan 1, 1981

By J. H. Rowland, A. C. Smith, K. A. Teacoach

Current regulations for fire suppression systems in underground coal mines to protect conveyor belt installations have been in place since the Coal Mine Health and Safety Act of 1969 was enacted. Over time, the coal conveyer equipment being used and ventilation conditions underground have changed significantly, particularly the width of the conveyor belts and the use of belt air at the face. The effect of these new conditions on the effectiveness of suppression systems during a fire is not known. The National Institute of Occupational Safety and Health (NIOSH) conducted a study to evaluate the effect of air velocity, water sprinkler activation temperature and a limited water application time on the effectiveness of water sprinkler fire suppression systems to extinguish large-scale conveyor belt fires. The fire tests were conducted using both new and used 1.8-m-wide, fire-resistant rubber belt that met the Mine Safety and Health Administration (MSHA) flame-resistant requirement specified in Title 30, Code of Federal Regulations, part 18, section 18.65 (also known as the 2G test). Tests were conducted using standard response sprinklers with activation temperatures of 68° C and 141° C at air velocities of 0.5 and 5.1 m/s. Two tests were conducted at both air velocities for each sprinkler activation temperature, one using a new belt and one with a used belt. The results showed that the suppression system was able to suppress the fires in ten minutes to the point that a miner could extinguish it with a fire hose. However, in several of the tests, the fire reestablished itself a few minutes after the sprinkler water supply was cut off and quickly grew out of control. This report discusses the large-scale experimental configuration, the installation specifications of the fire suppression system and the results and conclusions regarding the effect of air velocity, sprinkler activation temperature and limited water application on the suppression system performance.

Jan 1, 2010

By O. Tshifungat, A. Luzanga, N. Goel, S. Sandoval

"Tenke Fungurume Mining Company (TFM), located in Katanga Province, Democratic Republic of Congo (DRC), began production of copper cathode and cobalt hydroxide in March 2009. Copper production capacity was 115 000 t/a utilizing a semi-autogenous grinding, agitated leach, countercurrent decantation process followed by solvent extraction and electrowinning (SX-EW). Cobalt production capacity (as cobalt hydroxide) was 8000 t/a utilizing a three-stage purification/precipitation process treating raffinate from the copper SX-EW process. Recently a phase II expansion was completed, in which copper electrowinning capacity was doubled and four stages were added to the SX plant. Corresponding enhancements were made to mining, milling, and processing to bring production to 195 kt/a copper and 15 kt/a cobalt. An additional sulphuric acid plant is currently being constructed, adding 1400 t/d sulphuric acid to bring total acid production to 2250 t/d for use in leaching at TFM.Initial copper electrowinning results were satisfactory, but cathode quality and current efficiency decreased as copper production increased. The Freeport-McMoRan (FCX) Technology Centre and TFM personnel began operation of two bench-scale copper electrowinning cells in the tankhouse to diagnose chemistry effects on the cathode and anode. The results indicated an excellent electrolyte chemistry, producing finely crystalline copper at 430 A/m2 current density with 98% current efficiency. Attention next turned to the physical factors of the electrowinning cells, including electrode insulator geometry and performance. A demonstration cell was selected in the tankhouse and was operated with varying cathode and anode insulator geometries. Operation of the demonstration cell with a three-side cathode edge strip, A-style anode insulators, and an improved cell furniture design increased current efficiency from 77% to 89% at 400 A/m2 current density. Cathode quality improved correspondingly. TFM is now operating at 92% current efficiency."

Jan 1, 2016

By John A. Meech, J. G. Paterson

Activated carbon is a strong adsorbent for amyl xanthate, capable of removing from solution up to a quarter of its own weight in xanthate. In selective flotation system where depression is unstable, separation efficiency increases with activated carbon additions. The improvements observed are brought about by two mechanisms. First, by removing stripped and residual collector ions from solution, competition between depressant and xanthate is reduced and depression is stabilized. In addition, the texture of the froth phase at high pine oil concentrations is modified by activated carbon such that better drainage between the air bubbles takes place, alleviating the mechanical entrapment of depressed mineral particles. In treating a bulk copper/lead concentrate produced from GECO ore, selectively between galena and chalcopyrite is increased when activated carbon is used. Although the rate of flotation of galena is marginally lowered by activated carbon, a small extension in the duration of flotation allows the lead recovery to increase by 19% at the same recovery of copper. An addition rate of 0.75 kg/ton (1.5 lb/st) of bulk concentrate is suggested as optimum from this testwork. However, the actual level used in the mill is dependent upon the residual concentrations of collector and frother in the bulk concentrate pulp.

Jan 1, 1979

By J. G. Paterson, J. A. Meech

Abstract-Activated carbon is a strong adsorbent for amyl xanthate, capable of removing from solution up to a quarter of its own weight in xanthate. In selective flotation systems where depression is unstable, separation efficiency increases with activated carbon additions. The improvements observed are brought about by two mechanisms. First, by removing stripped and residual collector ions from solution, competition between depressant and xanthate is reduced and depression is stabilized. In addition, the texture of the froth phase at high pine oil concentrations is modified by activated carbon such that better drainage between the air bubbles takes place, alleviating the mechanical entrapment of depressed mineral particles. In treating a bulk copper/lead concentrate produced from GECO ore, selectively between galena and chalcopyrite is increased when activated carbon is used. Although the rate of flotation of galena is marginally lowered by activated carbon, a small extension in the duration of flotation allows the lead recovery to increase by 19% at the same recovery of copper. An addition rate of 0.75 kg/ton (1.5 lb/st) of bulk concentrate is suggested as optimum from this testwork. However, the actual level wed in the mill is dependent upon the residual concentrations of collector and frother in the bulk concentrate Pulp.

Jan 11, 1978

By John A. Meech

In many multiple-sulphide ore flotation processes, it is desirable to concentrate each of the various valuable minerals into separate products. Although there are a variety of techniques and chemicals which can be employed to produce efficient separation, two basic types of flotation circuits are used: The Differential Flotation Circuit and the Bulk/Selective Flotation Circuit. Figure I depicts these two circuits in their most simplified form for the production of two concentrates and one tailing product. If three or more valuable minerals are present in an ore, a variety of combinations or extensions of these two basic flowsheets may be used. There are many examples of the successful application of both circuit types with ores containing similar minerals. Each ore must be tested individually to decide on which circuit is best. However, the following general statements can be made: 1) The differential circuit will have higher capital and operating costs than will the bulk/selective circuit due to higher rougher capacity requirement. 2) The differential circuit will achieve better separation than will the bulk/selective circuit since it is usually easier to reactivate a depressed mineral than it is to depress an already active mineral. If the deactivation problem with the bulk/selective circuit . . in can be overcome, there is a clear economic argument for its use

Jan 1, 1977

By C. Ottergren

A process does not have higher capacity than what can pass through its bottleneck. Acknowledging this, and with the goal to optimize production at a minimum investment, one can use existing equipment, modify the process flow and make a few strategic capital investments. Automatic setting regulation is a technology that allows balanced crusher performance matching minute changes in feed material characteristics. The system makes it possible to utilize the crushers fully at all times. It also continuously and completely compensates for manganese liner wear.

Jan 1, 1999

By C. Ottergren

A process does not have higher capacity than what can pass through its bottleneck. Acknowledging this, and with the goal to optimize production at a minimum investment, one can use existing equipment, modify the process flow and make a few strategic capital investments. Automatic setting regulation is a technology that allows balanced crusher performance matching minute changes in feed material characteristics. The system makes it possible to utilize the crushers fully at all times. It also continuously and completely compensates for manganese liner wear.

Jan 1, 1999

By Dennis Nottingham

Increased interest in seismic soil liquefaction and preventative soil stabilization sets the stage for improved deep compaction methods using pile driving techniques. In 1971 L.B. Foster Company personnel patented a method of deep compaction using a vibratory pile hammer and pile probe. The technique had some success, but did not produce consistent results and thus found its way to obscurity. Other patents attempted to modify the technique by various probe modifications, but again without measurable improvement from a practical point of view. Solutions to economical deep compaction up to 100-foot depths particularly in saturated granular soils would have a great impact on the construction industry and new bulkhead structures being developed, thus PND was prompted into related research and development. The advent of higher horsepower vibratory hammers, coupled with PND engineers' experiments, observations and measurements, led to an "H" pile probe design which has produced measured soil density improvements up to 250% using SPT "N60" values as a measure. Case histories of two projects involving extensive SPT soil sampling comparative measurements will be discussed along with findings that led to the compaction success. Applications to numerous modern "Open Cell" bulkhead projects will be presented and discussed.

Jan 1, 2004

By Dennis Nottingham

"Increased interest in seismic soil liquefaction and preventative soil stabilization sets the stage for improved deep compaction methods using pile driving techniques. In 1971, L.B. Foster Company personnel patented a method of deep compaction using a vibratory pile hammer and pile probe. The technique had some success, but did not produce consistent results and thus found its way to obscurity. Other patents attempted to modify the technique by various probe modifications, but again without measurable improvement from a practical point of view. Solutions to economical deep compaction up to 100-foot depths particularly in saturated granular soils would have a great impact on the construction industry and new bulkhead structures being developed, thus PND was prompted into related research and development. The advent of higher horsepower vibratory hammers, coupled with PND engineers’ experiments, observations and measurements, led to an “H” pile probe design which has produced measured soil density improvements up to 250% using SPT “N60” values as a measure. Case histories of two projects involving extensive SPT soil sampling comparative measurements will be discussed along with findings that led to the compaction success. Applications to numerous modern “Open Cell” bulkhead projects will be presented and discussed.INTRODUCTIONNecessity often is the basis for innovation and such was the case for needed cost-effective deep soil fill compaction in Open Cell bulkheads where granular fill below water levels was often placed.Open Cell bulkheads were developed by PND Incorporated starting in 1980, for the express purpose of meeting client demands for an economical, easily constructed, extremely strong structure. Earth-filled structures historically have had a long history of problems with stability, scour and settlement.Open Cells are flexible steel sheet pile membranes supported by soil contact with embedded tail anchor walls.This concept creates an integral reinforced soil system. The result is a structure that can withstand large settlement and support a variety of very large loads. In effect, viewed from above the structure becomes a series of U-shaped horizontal membranes that require no toe embedment for stability. The Open Cell bulkhead is constructed of only three components: flat sheet piles, fabricated connector wyes and anchor piles. Compared to alternative structures, several cost savings are realized from this land based construction such as, reduced sheet pile area, greater construction tolerance, minimal pile penetration, and simplified backfilling procedures. In seismic regions or weak soils, the tail walls can be extended as required to guarantee fill mass stability."

Jan 1, 2005

By David R. Macedon

"Through the years, a wide variety of dust control methods have been utilized at mineral processing operations. While some have been successful, many have been highly ineffective. Dust Control systems currently in use include baghouse systems, fog systems, surfactant spray systems, and foam dust suppression. While baghouse systems can be effective, they are capitalintensive and costly to operate and maintain. Chemical dust control programs can be very effective. However, if applied incorrectly, they can have detrimental effect on mineral recovery. Thus, many operations utilize a combination of baghouses and water, often with limited success.Recent advancements in surfactant and polymer chemistry have resulted in substantially improved chemical dust suppression programs. These products range from non-corrosive surfactant/humectant combinations for road dust control to foam-based systems for crushers and transfer points, to advanced polymers for pile binding and soil stabilization. These advances are discussed in detail, citing results from fieldwork in the precious and base metals industries.INTRODUCTIONThe global nature of the mineral processing industry presents a unique set of challenges. Traditional thinking would tell us what works in one place should work in another. This could not be further from the truth in the area of dust control. We learn very quickly that there are a number of factors that can affect the efficiency and success of a dust control program and that these factors are not all chemical or equipment related. Some of these factors include facility maintenance, product selection, water quality and characteristics, and economic considerations.What has been learned from past experience is that each mineral processing plant presents a unique set of factors that will affect the ability to create an optimal dust control program. This paper presents a myriad of treatment options that will highlight the advancements in chemical dust suppression products and equipment."

Jan 1, 2004

By D Reid, J Vinod, M Rahman, A Fourie, T Vo, J Ayala, A Russell

This paper reports on an industry and Australian Research Council funded research project, TAILLIQ, that is a joint initiative between four Australian Universities. The paper discusses the accuracy with which the critical void ratio can be determined for a given tailings; it does this by presenting the results from a ‘round robin’ study in which 18 geotechnical laboratories around the world participated, testing the same tailings (sampled from a gold mine in Western Australia). The results were variable, although a reasonable number were very similar, as described in the paper. The paper provides additional test data for sandy silt gold tailings recovered from a sponsor’s site in Australia, including preliminary calibration chamber test data, results from direct simple shear tests and characterisation tests to determine unsaturated geotechnical properties.

Jul 1, 2021

By William B. Thayer, James H. Meinholz

The Milwaukee Metropolitan Sewerage District (MMSD) has been working since mid-1977 on a fast track to meet a court-imposed schedule to rehabilitate a large wastewater collection and treatment system at an estimated cost of $1.7 billion. Because of glaciation, the Milwaukee area has an extremely complex geologic environment. The rock surface ranges from outcroppings in the northern and western parts of the area to 76 m (250 ft) below the surface at the mouth of the Milwaukee and Menomonee Rivers. Bedrock beneath the glacial mantle is a thick sequence of early to middle Paleozoic sedimentary rock. To cope with the many complexities of this large public works project, a Program Management Office (PMO) concept has been employed. A Geotechnical Engineering Group was established within the PMO to provide a continuous , unified approach to geotechnical engineering and full disclosure of all geotechnical information in the construction contract documents. It provides qeotechnical engineering to design and construction, develops and maintains a qeotechnical data base, and participates on the claims resource team.

Jan 1, 1983

By Rosentreter N

Difficulties with froth flotation recovery and vacuum de- watering equipment for the treatment of fine coal have been investigated. Mechanical alterations to cyclone desliming banks, and flotation cells are described. A large disc filter has been replaced by two drum filters for dewatering, and the improvement in plant. operation is discussed:

Jan 1, 1978