Search Documents

By S. S. Klima, J. A. Organiscak

Researchers at the National Institute for Occupational Safety and Health (NIOSH) performed laboratory testing to examine and improve airborne dust capture and methane removal performance of flooded-bed scrubbers on continuous mining machines using a blowing face ventilation configuration to reduce respirable dust exposure to shuttle car operators. Several testing conditions were examined to minimize shuttle car operator dust exposure without adversely affecting continuous miner performance and production. Curtain-to-face setback distance of 9.1 m versus 15.2 m (30 ft versus 50 ft), face ventilation airflow of 226.5 m3/min versus 339.8 m3/min (8,000 ft3/min versus 12,000 ft3/min), and the use of side-body-mounted blocking sprays (on versus off) were the three primary parameters compared. Scrubber airflow was set and maintained at 198.2 m3/min (7,000 ft3/min) throughout testing. An examination of slab cuts versus box cuts and the location of the shuttle car (present behind the continuous miner versus not present in the entry) was also performed to demonstrate the effects of these constantly changing scenarios on scrubber performance. Results show that the best blowing face ventilation setup for minimizing shuttle car operator dust exposure for the tested parameters uses a 15.2-m (50-ft) curtain-to-face setback with 339.8 m3/min (12,000 ft3/min) face ventilation while operating the side-body-mounted blocking sprays. INTRODUCTION Coal mine worker overexposure to respirable coal dust continues to be a problem in U.S. underground coal mining operations, potentially leading to coal workers’ pneumoconiosis (black lung). The U.S. Mine Safety and Health Administration (MSHA) requires that respirable dust exposure to coal mine workers does not exceed a 1.5 mg/m3 average over the actual working shift (79 Fed. Reg. 24814 (2014)). Although using a blowing face ventilation configuration on continuous miner (CM) sections is beneficial for removing methane emissions from the mining face, it can be detrimental for dust control for shuttle car (or ram car) operators and any other workers on the return ventilation side of the CM when compared to exhausting ventilation. Even with machine-mounted scrubbers on CMs, shuttle car operators still have some of the higher dust exposures with blowing face ventilation systems (NIOSH 2011, Beck et al. 2015). Although scrubber discharge air is not completely clean, dust being blown around the scrubber inlet and therefore not being captured by the scrubber can further increase these dust exposures (Goodman 2000). Dust control problems are also caused by inadequate face ventilation quantities causing scrubber face airflow recirculation issues (Schultz et al. 2010). In order to minimize respirable dust exposures on blowing face ventilation sections, ventilation, water spray, and scrubber parameters were experimentally examined to improve operating ranges for both dust and gas control. Several blowing face ventilation factors were examined with respect to CM spray systems and scrubber operation. Curtain-to-face setback distance and side-body-mounted blocking sprays were previously examined in the laboratory for dust control on a full-scale CM model using a scrubber on a blowing face ventilation system (Goodman 2000). The blocking sprays produced larger dust reductions at the CM’s rear corners and return for a 6.1-m (20-ft) curtain setback distance as compared to a 12.2-m (40-ft) curtain setback distance with equal face and scrubber airflows of 169.9 m3/min (6,000 ft3/min). Because face ventilation airflow quantities, shuttle car operator locations, and tracer gas concentration gradients were not previously examined during these experiments, additional research was required to determine improved operating parameters for blowing face ventilation systems.

Jan 1, 2019

By Gerald H. Luttrell, Jaisen N. Kohmuench, Michael J. Mankosa

A new separator, known as the Hydrofloat cell, has been developed to overcome limitations of traditional flotation cells in recovering coarse particles. In this process, small air bubbles are introduced into a hindered "teeter" bed of fluidized solids to create light bubble-particle aggregates that can be separated based on differences in density. Laboratory tests conducted with coarse phosphate feeds indicate that the Hydrofloat cell is capable of increasing BPL recoveries by nearly 20% over conventional flotation methods. Based on these encouraging results, a pilot-scale Hydrofloat cell was fabricated and installed at a central Florida phosphate plant. Test data collected using the pilot-scale unit suggest that the BPL recovery of the plus 35 mesh plant feed can be increased by more than 40% through the application of this new technology. This improvement is particularly beneficial due to the very high grade (-73% BPL) of the plus 16 mesh particles in the Hydrofloat concentrate. This article describes the theoretical basis for the development of the Hydrofloat cell and provides an overview of recent laboratory and pilot-scale test results.

Jan 1, 1999

By H. P. Hatch

Ash is a material that many people leave to nature to handle. Others sometimes sweep it under the rug to be disposed of by someone else. In our business we cannot do either. In fact the American Electric Power System spends many millions of dollars in plant investment costs to collect the material, and then many more millions to dispose it. In 1965 alone the coal fired steam generating plants in., the AEP System produced approximately 2,400,000 tons of ash, enough to fill 40,000 coal cars which would extend as a single train across the entire states of Ohio and Indiana. Even though our present ash production is large, this is only the beginning when we forecast the future growth of our system. By 1980 it is estimated that our generating capacity will expand to about three times its present size, and with coal as our primary source of fuel our ash production will increase proportionately to about 7 million tons a year.

Jan 1, 1966

By Vincent C. Grimshaw

High pressure fluid energy grinding, or jet milling, is a versatile method of continuously fracturing solids into fine particles to gain substantial increases in exposed surface area. Applications in the minerals industries include calcium carbonate, talc, barytes, mica, diatamaceous earth, bauxite, rutile, coal, kaolin, sepiolite, diamonds, etc. The basic principles can be extended to provide continuous drying and delivery of discrete particles from a wet process slurry. The main design and operational features of jet mills and dryers are described, relating energy consumption for both air and steam milling and hot air drying techniques. Mean particle sizes in the order of 1 micron are achieveable from pre-milled feeds, or maintained from similar slurries in the drying mode. Aspects of feed preparation and multi-stage processing are discussed.

Jan 1, 1983

By Vincent Tricot, Daniel Altier, Roger Storry

"INTRODUCTION The Liantang / Heung Yuen Wai Boundary Control Point (BCP) project, located in the north-east New Territories of Hong Kong, will form the seventh land crossing between the Hong Kong Special Administrative Region (HK) and Shenzhen in China (Figure 1). The BCP project comprises an 11km long dual two-lane trunk road linking the border crossing facility to the existing road infrastructure in HK and when completed it will facilitate future regional development and alleviate frequent traffic congestion at the existing Boarder control points.In December 2013 Dragages Hong Kong (a member of the Bouygues Construction Group) was awarded the 5.4km long Contract 2 section of the project, including the 4.8km long Lung Shan Tunnels, by the Civil Engineering and Development Department of the Government of the HK SAR. To overcome the difficult ground conditions anticipated along the Contract 2 section of the project the tunnels will be constructed using mechanical and drill and blast (D&B) excavation techniques together with a 14.1m diameter multi-mode Earth Pressure Balance Tunnel Boring Machine (TBM). Land constraints imposed on the project alignment require that the final 500m section at the northern end of the Lung Shan tunnels, under Princess Hill (Figure 2), takes an almost 90 degree turn towards the north. The resulting 354m radius curve restricts the sight-line of road users to below the minimum 110m at 80km/hr hence, the internal span of the tunnels needs to be increased from 12.6m, in the standard straight section, to 15.4m in this curved section to accommodate a widened shoulder which will provide the required sight-line distance."

Jan 1, 2016

By S. Tuylu, D. Adiguzel, U. G. Akkaya, A. Bascetin

"One of the main problems for storing of the tailings is acidity occurrence due to several factors such as existence of sulfuric minerals and also the pollution in seepage waters by mobilization of metal ions, which holds great risks in terms of environmental regulations. Because of these specified reasons, tailing materials to be used in a SPD formula should have comply with some specifications. Among these properties; oxygen content, temperature, matrix suction and pH are the most important parameters. In the study, the relationships between the parameters mentioned are investigated to reveal optimum paste design layout. The lowest amount of seepage water obtained from the paste layers in the pilot cabinet was found as 2150 ml from 3rd layer. As for the maximum seepage water and the average of the all 11 layers were found as 4909 ml from 6th layer and 3273 ml respectively. The reactions occurring according to the oxidation, as seen at seepage water of second and third layers, decreased the pH of system to the under of 7 value. Additionally, when the seepage water of first layer’s EC value is 2.93 mS/cm, the EC value of second layer is increased at 3.54 mS/cm. The other parameters are evaluated with the obtained results of the tests to determine the optimum storing conditions for SPD.INTRODUCTION Conventional waste disposal methods, although widely used, pose great environmental risks. One of the most important issues is acid mine drainage (AMD). Tailings of metallic mines contain heavy metals, aggressive chemicals and hazardous materials. In the presence of oxygen and water, an oxidation reaction can occur, causing a decrease in pH of the environment, and heavy metals that are present in the environment can dissolve easily. Subsequently, heavy metals can pollute underground water basins, creating a great amount of danger for the ecology and potable water resources. Another important risk associated with conventional waste disposal methods is accidents related to the waste dam. Higher volumes of water and tailings (usually 15% solids and 85% water by weight) are sent to waste dams, making it very difficult to control the stability of the dam under conditions such as static and dynamic loads (seismic activities, vibrations caused by blasting, etc.), flooding, and seepage. In case of an accident or failure, the spread of great amounts of mud containing hazardous chemicals and heavy metals can harm the environment of the dam site significantly (Bascetin et al., 2014). In the paste technology, depending on the type of ore, tailings used in the paste mixture can contain sulphide minerals (such as pyrite and pyrrhotite). These minerals are known to be reactive with water and oxygen to produce acidity (sulphuric acid)."

Jan 1, 2015

By G. J. Trezek

The use of polysilicates for treating heavy metals in soils and mining sludges is discussed. Results of the treatment are given for soil contaminated in a metal scrap yard operation and for copper mining processing sludges. The types of metals of concern are arsenic, lead, copper, nickel, cadmium, and zinc. The application of the treatment is predicated on the mixture and relative concentrations of the metals as well as the material matrix. Reductions in soluble concentrations (STLC or TCLP) of one to two orders of magnitude can be achieved with relatively small additions of silicates and cementitious materials.

Jan 1, 1992

By S. Tuylu, D. Adiguzel, A. Bascetin, E. G. Savas, O. Ozdemir

"Paste Technology has some advantages comparing to other surface disposal methods. With this method, it is possible to pump high concentrated solid materials to very long distances without segregation problem. However, it is known from Literature that pumpability of materials is completely related to rheological properties of the materials. For this reason, in this study, the rheological parameters (e.g. yield stress and viscosity values) of the paste material prepared from Pb-Zn tailings at various solid ratios (60-85%) were obtained in order to determine the pumpability of the paste material. Additionally, slump tests, which are usually used in mining industry, was carried out. Finally, regression analysis was made between the slump values and rheological parameters of the paste material to find a correlation between two independent parameters. The results showed that there is a great correlation between the slump values and the yield stress of the material. On the other hand, there was no correlation with viscosity: ty=430.28-16.877Sv (R2= 0,94; ty: Yield Stress (Pa), Sv: Slump Value (cm)). Based on the results obtained from this study, it can be clearly concluded that the slump values obtained from a simple test can be used to predict yield stress values of paste materials. INTRODUCTION Recently, surface disposal of mining tailings has become one of the biggest problems in mining industry in terms of environmental issues. Therefore, several researches have been focused on this subject in order to find a best solution or method for this problem. These studies showed that paste technology has some advantages compared to other conventional methods. Tailings thickened to the extent show no segregation of particles during transportation, and relatively small amount of settling occur post-deposition which are often called “paste” (Cincilla et al. 1997). Paste tailing technology has two applications in the industrial area as underground paste fill and surface paste disposal. Paste tailing technology was first started to be used in Grund mine, Germany in the late 1970s (Grice, 1998). Process tailing material, water and - if needed - cement materials, which are the components of the paste, must be blended to obtain a homogenous mixture suitable for pumpability. Consistency behavior of the paste material is determined using a conventional sedimentation cone concrete test (slump). Meanwhile, the slump value of the paste must be between 200 and 250 mm for surface applications (Newman et al., 2001). Additionally, in the case of underground paste system, the optimum slump value must be between 150 and 200 mm. On the other hand, the water content and density of paste at certain slump value change depending on the amount of fine particles in the tailing sample. While moisture of the material will be high, its density will be low because of surface area of particles which increases with decrease in particle size (Meggyes and Debreczeni, 2006). For pumpability of the paste to long distances, slump value of the paste must be good enough to be accepted for use of surface paste disposal. Paste material has a yield stress because they show non-Newtonian behavior and generally is classified as a Bingham plastic fluid. (Cooke, 2008; Theriault, 2003). In addition, the appropriate viscosity value of the paste along with the yield stress must be between 100 and 250 Pa (Bascetin et al., 2013; Bascetin et al., 2014; Bascetin et al., 2015)."

Jan 1, 2016

By Rambabu Pothina, Rajive Ganguli

The economics of a mineral-processing circuit is dependent on the numerous sensors that are critical to optimization and control systems. When a sensor goes off calibration, it results in errors that can have a severe impact on plant economics. Classical statistical approaches fail to detect when errors are “subtle,” unless they grow and become large enough to be “gross,” whereas methods based on signal processing and artificial intelligence fail in dealing with the complexity of process fluctuations. Due to the sheer volume of sensors, undetected errors are not remedied until the next calibration, which on average are a year apart across all industries [1]. This research aims to detect such subtle errors (2 percent bias) in shorter time spans of about a month — rather than wait for errors to grow — using innovative data-mining techniques and algorithms.

By Bruce C. Trent

The need for effectively evaluating the potential for surface subsidence due to under- ground mining has been widely documented. As the emphasis within the coal mining industry changes to reflect the increasing demand of this resource, the potential for damage due to differential surface subsidence will certainly become more acute. The present state-of-the-art of predicting ground motion due to underground excavations is, at best, primitive when one considers the immense complexity of possible geological inter- actions. For the most part predictions have been limited to empirical evaluations based upon earlier case histories. While the tools of the subsidence engineer are limited, they are important and serve to provide reasonable bounds for possible ground motion. As underground mining becomes more extensive, however, there will be many instances where excessive subsidence will be most undesirable and yet there may be few, if any, case histories similar to the operation in question.

Jan 1, 1982

By Robert L. Vines

"What is past is prologue" - motto of National Archives The question of past, present, and future safety performance in the coal mining industry is not merely an academic one, or one which arises from soul-searching curiosity. It is a question involving pragmatic ramifications, and the answers, or perhaps the public perception of the answers, will have a strong impact on the public policies which influence the course of meeting the Nation's future energy demands. Those of us in the coal industry are keenly aware of the significant impact of the public reaction -- in the form of the 1969 Health and Safety Act -- to -past performance of the coal industry which it found unacceptable. That Act was revolutionary -- and it was expensive. But in finding the industry's past performance unacceptable, the public also recognized its own contributory role through having enjoyed a "buyer's market" forced on a highly competitive industry. One result was to limit the industry's resources and restrict its ability for self-improvement of its safety performance. In acknowledgement of that role, the public picked up the tab for Black Lung disability incurred prior to that time.

Jan 1, 1985

By D. A. Bird

Geochemical models using published thermo-dynamic data and laboratory derived kinetic rate laws allow prediction of post-closure pit lake geochemistry at open pit mining sites. A combination of "forward" and "inverse" modeling techniques can predict the pit lake geochemical evolution from initial infilling to eventual steady state attained decades or centuries after closure. Computer codes have been developed to model chemical reactions such as pyrite dissolution, describe the ground-water flow regime, and provide rock-water ratios. The incorporation of site specific information, such as ultimate pit dimensions, geologic and hydrologic data, acid generating potential (AGP) vs. acid neutralizing potential (ANP), and laboratory derived kinetic rates, allows application of the model to open pit mines at any stage of development.

Jan 1, 1994

By A. R. Rule

As part of the Federal effort to help maintain an adequate supply of fertilizer minerals, the Bureau of Mines is conducting research to characterize complex, low-grade western phosphate rock and to develop methods for economic recovery of phosphate. The rock varies from soft, friable, altered phosphatic shale to hard, tightly cemented, unaltered phosphate rock. To supplement current beneficiation by sizing, a flotation procedure was devised that included depression of phosphate minerals with H2SiF6 and anionic flotation of carbonate minerals, followed immediately by cationic flotation of silicate minerals. Application of the procedure to several different ores resulted in phosphate concentrates that ranged from 28 to 31 pct P20S in grade and from 60 to 70 pct in phosphate recovery.

Jan 1, 1977

By R. L. Garrett

The quality of mineral additives used 1n a drilling fluid (mud) can dramatically affect the fluid's properties and the overall cost of drilling an oil or gas well. The principally used minerals are bentonite, barite, barite/hematite blends and hematite alone. The high specific gravity minerals, barite and hematite, are used to increase drilling fluid density. Bentonite clay is used to increase drilling fluid viscosity, gel strength and to provide a low permeability filter cake. A multi-million dollar investment in a well and the safety of the personnel on the drilling rig can depend on how effectively these mud additives perform with other constituents in the mud. This paper points out effects caused by small amounts of certain carbonate and sulfide mineral impurities in barite or hematite and how polymeric extender additives in bentonites contribute to unpredictable behavior of a mud. Effects like these are the reason why oil companies who use these materials sometimes set their own quality standards beyond those already specified in API Spec. 13A. Also discussed in this paper are the current standardization activities in API Committee 13 on these minerals.

Jan 1, 1986

By Jon A. Hummer, Aleksandar D. Bugarski, Shawn Vanderslice, Teresa Barone

Reducing the contribution of heavy- and light-duty diesel-powered equipment to concentrations of aerosols and gases is essential to industry’s efforts to improve air quality in underground mining operations. The results of this study demonstrated a potential of control strategies based on retrofitting existing power packages with diesel oxidation catalyst (DOC) and diesel particulate filter (DPF) systems and repowering existing systems with advanced power packages to reduce contributions of diesel-powered vehicles to concentrations of diesel aerosols and criteria gases in underground mines. The implementation of viable exhaust aftertreatment systems and advanced diesel power packages could be instrumental in the underground mining industry securing a clean, economical and dependable source of power for mobile equipment.

By Thomas Novak, Sampurna Arya

Controlling dust generation and keeping it below permissible limits to meet federal dust standards at the working face of a room-and-pillar coal mine is a challenge for a mine operator. With the recent changes in federal dust regulations requiring lower worker exposure, maintaining compliance has become increasingly difficult. The current most effective practice of dust control at a continuous miner face in an underground mine is the use of a flooded-bed scrubber. A study carried out by the U.S National Institute for Occupational Safety and Health (NIOSH) indicated that a flooded-bed scrubber could achieve cleaning efficiencies between 58 and 90 percent. But the operation of such a system is maintenance intensive. The flooded-bed scrubber screen becomes clogged with dust particles and requires frequent cleaning to maintain performance. However, the dust control issue is not solely a mining-industry problem. Other industries face similar issues. The University of Kentucky collaborated with Toyota Motor Manufacturing on the development of a novel wet scrubber, called the vortecone scrubber, for capturing over-sprayed paint particles in automotive paint booths. The vortecone scrubber achieved a cleaning efficiency of 99 percent and required minimal maintenance. This study aims to assess the ability of this vortecone scrubber to capture respirable dust in an underground coal mine. The paper presents the results of computational fluid dynamics (CFD) modeling of this vortecone scrubber. It discusses the effects of air quantity and dust particle size on the performance of the scrubber. 

By R. Gray, B. Hebblewhite

Experience from Australia had identified what is referred to as nonconventional surface subsidence behavior. This occurs under irregular surface topography, resulting in valley closure, valley floor uplift or “upsidence,” and far-field horizontal movements, occurring even beyond conventional “angle of draw” limits. This paper discusses such behavior recently observed in Pennsylvania and focuses on the 2005 case of Duke Lake Dam in Ryerson Station State Park. In July 2005, there was a significant increase in water leakage through a number of growing cracks in the dam, leading to the dam being breached to avoid an uncontrolled failure. An underground longwall mine was located approximately 900 ft to the north, mining at depths of 330 to 720 ft. Investigations, including a subsequent ground movement monitoring program, found a range of evidence in the vicinity suggesting that valley closure and farfield horizontal movements may have occurred, resulting from the adjacent mining. Besides discussing the phenomenon of nonconventional subsidence behavior and the Ryerson State Park case study, this paper includes an assessment of the mining, geology and subsidence impacts and suggested ground behavioral mechanisms.

Jan 1, 2015

By K. K. Bhattacharyya

In the Gulf Coast area lignite deposits occur in Texas, Louisiana, Arkansas, Mississippi and Alabama. Lignite has been mined in Texas since the early 1800's reaching a production of over 900,000 metric tons (1 million short tons) in 1910. With the availability of inexpensive oil and gas, production fall to as low as 16,000 metric tons (18,000 short tons) by 1950 (Henry, 1976). With the advent of the oil and gas shortage in early 1970, lignite production began to increase again. The purpose of this paper is to discuss the geotechnical considerations of mining lignite in the Gulf Coast area, particularly Texas and Louisiana. Lignite deposition occurs in unconsolidated sand, silt and clay environments. Extensive sand units saturated with water may be present within the potential mining depths. This paper describes the geotechnical considerations for designing a surface mine in this geographical area. These factors include geology, hydrology, mining method, and equipment utilization.

Jan 1, 1982

By James S. Browning

In 1975 bituminous coal and lignite production in the United States reached an all-time high of 637 million tons, an increase of 6 percent over production in 1974. The output, valued at $11.9 billion f.o.b. mines, was produced at 5,100 mines in 24 states (6). Coal mining is the largest mining industry in Alabama. Production from Alabama's mines in 1975 was over 21 million tons, and present projections forecast a steady increase in production, with tonnages almost doubling by 1985 (5). Of the total quantity of coal produced, about 16 million tons were consumed in electric power generation and the remainder was used for metallurgical coke production, extraction of chemicals and petroleum based products, and power for industry. The fact that 75 percent of Alabama's power is generated by burning coal attests to the importance of this fossil fuel to the State. Approximately 14 million tons of coal were produced by strip-mining methods in Alabama during 1975 and about 7 million tons were produced by underground mining during the same period. Surface mining is expected to continue at about 14 million tons per year, but by 1980 underground coal mining is expected to increase to about 25 million tons (3). About 7 million tons of surface-mined coal in Alabama is subjected to some means of washing or cleaning. The methods used are screening accompanied by heavy media separation, jigging, tabling and flotation. Some of the simpler approaches employ screening and jigging, or tabling. Except where flotation is used, the screen undersize fraction (finer than 0.25 inch) is rejected, with the result that 10 to 15 percent of the coal is lost. Thus, in the State of Alabama an aggregate of about 1 million tons of coal is wasted annually in the fines which are impounded from treatment of surface-mined coal. The use of the Humphreys spiral to concentrate fine coal was practiced as early as 1947. At that time the Hudson Coal Company (1) used Humphreys spirals to concentrate anthracite fines. In 1950, the use of spirals to treat fine-size

Jan 1, 1977

By J. L. Mehaffey

A variety of chemicals offered by Armak were evaluated as dewatering aids for aqueous slurries of silica sand, sparsand and feldspar; an established commercial dewatering aid was used as a control. A number of Armak's potential dewatering aids yielded lower moisture retention values than did the commercial product on all of the mineral samples. In addition to the chemical dewatering evaluations, some of the mechanisms involved in the removal of water from these mineral samples were examined.

Jan 1, 1983