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By Y. P. Chugh

This is the final report of a study done by IIT Research Institute for the Bureau of Mines to identify the problem areas and technological inadequacies in noncoal (metal, nonmetal, stone, and sand and gravel) mining and processing systems that are the primary causes of death, injury and occupational disease, and to make recommendations to improve safety and health in these operations. The findings and recommendations presented in the report are based on: (1) analyses of MESA injury and employment data for the period 1961-70, MESA fatality reports for underground noncoal mines (1968-72) and lost time accident data for 1970-72 obtained from mining and processing operation: (2) visits to a variety of noncoa1 mines and mills throughout the country to observe the operations and to study the safety organization and practices used in the industry and (3) interviews with industry and government representatives knowledgeable in the field of noncoa1 mining and processing safety and health. The report provides a comprehensive overview of safety and health problems.

Jan 1, 1974

By D. I. Smith

Constructing tunnels in congested urban areas requires tunnels to be placed closer together and with less cover than was previously necessary. Contract CQ031 of New York?s East Side Access project will construct four six-meter diameter bored tunnels in a three-up one-down ?T? configuration, with less than three meters of soil between the tunnels. Mixed-face rock and glacial till conditions with a high ground water table will be encountered under active railroad yards. The tunnels will also pass beneath the busiest railroad interlocking in North America with cover as shallow as three meters. This paper discusses the challenges of designing segmentally lined tunnels for these conditions.

Jan 1, 2008

By Aaron S. Bradshaw, Ryan M. Coulson

The offshore wind industry in the United States is slowly emerging with the recent construction of the first offshore wind farm located off the coast of Rhode Island. The turbines at the Block Island wind farm are supported by piled jacket structures, which historically have been used for much heavier oil and gas platforms. Offshore wind turbines have unique design requirements and the axial behavior of the supporting piles under cyclic loading is important to design. Cyclic degradation along the pile shaft can affect the capacity, deformation, and stiffness performance of the foundation and of the structure as a whole. This paper proposes a strain-based approach to estimate the fatigue (or endurance) limit of a cyclically loaded pile that may be applicable to long-term service loading. The method is applied to an existing load test dataset and the analysis results appear consistent with the observed pile response. INTRODUCTION The demand for renewable energy has been increasing in recent decades and wind power has seen a dramatic increase in popularity. In Europe, as of 2017 there were 4,149 grid-connected offshore wind turbines across 11 countries (windeurope.org), many of which are supported on monopile foundations. It wasn’t until recently (2016) that the first offshore wind farm was constructed in the United States off the coast of Block Island, Rhode Island. The project included 5 piled jacket structures founded in terminal moraine deposits. Future offshore wind development along the U.S. eastern seaboard could possibly utilize jacket structures in granular foundation soils. Loads from wave, wind, and turbine rotation induce cyclic loads on the foundation that have on the order of 108 loading cycles over the service life on the structure (Schneider and Senders 2010). Turbines located along the U.S. east coast have the added risk of hurricanes. As shown in Figure 1a, the lateral loads on a jacket structure are transferred primarily as axial compressive and possibly tensile loads on the supporting piles depending on the weight of the structure. The friction along the shaft of the pile can be prone to cyclic degradation, leading to reduced pile capacity and stiffness, and increased deformations. An offshore wind turbine foundation must be designed for a variety of limit states including ultimate, serviceability, and fatigue limit states. For a jacket structure this would include an analysis of the ultimate axial pile capacity, axial stiffness, and axial deformations, all of which can be affected by cyclic loading both under extreme (i.e. storm) conditions as well as long-term service conditions. Axial pile stiffness is needed, for example, to estimate the natural frequencies of the structure as a whole and to assess dynamic and fatigue loads. The structure must be designed such that its natural frequency remains outside the loading frequencies of the waves and turbine blade passing frequencies to avoid resonance. Therefore, prediction of the axial response of the piles is important to the design of these structures.

Jan 1, 2018

By V. T. McLemore

Petrographic analysis of rocks is traditionally performed with optical microscopy using thin sections and point counting. However, this does not provide accurate mineral proportions for sedimentary, volcanic, and soil-like material, because rock fragments, groundmass, and matrix are not identified as specific minerals. In addition, groundmass phases in volcanic rocks can be too fine to identify individually, and making thin sections of intact soil-like material is difficult because much of the material is not well cemented. ModAn is a normative calculation that estimates modes ??by applying Gaussian elimination and multiple linear regression techniques to simultaneous mass balance equations? (Paktunc, 2001) and allows location-specific mineral compositions to be used. One of the features of ModAn that makes it appropriate for this study is that it can model one of several sulfide minerals. Mineral compositions for Questa minerals were determined from electron microprobe analysis and entered into ModAn. Then by combining and normalizing results, bulk quantitative mineralogy can be determined using ModAn, petrographic observations, electron microprobe analysis, clay mineral analysis, and the whole-rock chemistry of the sample.

Jan 1, 2009

By Genrich A. Denisov

Principles of ecologically friendly geo-technologies construction are formulated on the basis of the works of the leading scientists in the field of rational processing of mineral resources of the Russian Academy of Sciences. One of these concepts is a new direction in rotational disintegration of mineral and technogenic raw material with the purpose of effective subsequent enrichment. A large amount of practical experience has been accumulated in the industry on selective destruction by application of vibrational method on initial material with consideration of its physical-mechanical properties and mineral structure. This method is successfully realised in a conic inertial pulverisation devices constructed by Mekhanobr Institute (St.-Petersburg). A new construction of conical-inertial pulverisation with a modification of disintegration force has been developed recently at Mekhanobr Institute. It allows, in some cases, to increase selectivity of subdivision and to avoid over-disintegration. Advantages of “wet” subdivision methods in conic inertial disintegration devices are proved. The efficiency of such subdivision can be increased due to rational use of the phenomenon of a dislocation-dynamic diffusion. Its advantage is proved by the effect on disintegrated material by frequency-modulated variable electrical fields of low power. It was shown in industrial conditions, that the productivity of the spherical mill can be increased by 10 %, and that it also prevents ecologically harmful surface active substances (SAS) in milling zone and it reduces the dust content in the air. The techniques of tentative estimation of efficiency of various proceedings technogenic materials and their classification are created. The scientific fundaments of rational, ecologically friendly technology of processing and regeneration of various kinds of technogenic raw material are developed. A number of effective technologies on processing of wastes is developed and inculcated in concentration factories and metallurgical factories.

Jan 1, 2003

By Max J. Spendlove

The secondary copper industry is comprised of numerous enterprises which collectively employ many of the recovery and refining processes now used in primary plants as well as many other processes that are unique to the industry. Effective methods are used for identifying and segregating all types of scrap according to widely accepted standard classifications. Segregated scrap and waste materials usually require some preliminary processing to remove both valuable and deleterious associated constituents. Smelting, melting, alloying, and pyrorefining are common methods used for producing secondary metal, but operating techniques usually differ from primary metal operations because of the difference in physical and chemical properties of the respective raw materials. Some copper scrap is converted to copper chemicals rather than to refined metals or alloys. Recovery efficiencies of all processes are reasonably high, and the quality of products meets rigid specifications.

Jan 1, 1961

By Mandeep Singh

The smelting of lead ores has been carried out in southeast Missouri for centuries, and modern smelting practices have generated a variety of waste products. Lead blast furnace slag is one such product, which typically contains 10% zinc, 25% iron and 2% lead. This slag has often been stockpiled on the producing smelter site and accumulations have now reached several million tonnes. It is possible that in the near future these slags will be classified by the federal Environmental Protection Agency as hazardous, and therefore there is considerable interest in possible treatment processes to render the slags non-hazardous by removing the offending metallic elements. To ensure that the overall slag processing costs are kept to a minimum, it is imperative that lead and zinc be recovered in a form suitable for sale or further processing. There are two generic routes for processing blast furnace slags and they involve hydro-metallurgical or pyrometallurgical techniques. With hydrometallurgy, the slags would be leached directly and the metal values recovered from purified leach solution(s) by electrowinning. One problem with processes of this type is that the zinc and lead grades of the slags are low and the iron content is high, and thus the economics of metal production are often not favorable. For pyrometallurgical processing (1), it has been shown that the slags can be fumed to produce an oxide dust containing all the lead and zinc, and representing only a fraction of the weight of the initial slag. The oxide dust may then be processed hydrometallurgical to recover zinc and lead.

Jan 1, 1992

By G J. Lyman, F S. Bourgeois

As the prices of metals slide, financial control of mineral processing operations becomes more and more important. Control of a mineral processing operation implies measurement of grades, recoveries and losses, with every effort being made to recover more product from the same feed. Shareholders become more concerned with the transparency of the operations and the corporate governance.There is only one way to achieve this and this is by sampling and making good use of the results of that sampling. Sampling systems that provide only 'rough' figures are not good enough. Similarly, a competitive position in the marketplace demands close control of product quality. Maximisation of product output demands that the product just meet the specification so that product yield is maximised. Decisions based on precise sampling results carry less risk that those based on imprecise results.This paper reports some recent advances in sampling theory that permit full quantification of sampling distributions, not just the sampling variance as has been possible in the past. These advances can be used together with simulation methods to tie down sampling precisions and develop calculations that quantify decision making risk when using the sampling results. A number of examples illustrate the use of the new advances and a final example indicates the development of risk analysis curves in the coupling of sampling precision to sale of a commodity.CITATION:Lyman, G J and Bourgeois, F S, 2015. Sampling, corporate governance and risk analysis, in Proceedings MetPlant 2015, pp 27–34 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By S. Shrivastava, R. G. Reddy

Spent potliner is generated in the electrolytic process of reducing alumina to make aluminum metal using molten fluoride electrolytes. Spent potliner (SPL), obtained at the end of the pots life contains a small amount of cyanide and fluoride which present environmental problems. SPL became a listed hazardous waste under RCRA (KO88) in July, 1990. One of the possible uses of spent potliner is as a substitute for Calcium Fluoride (CaF2) as a fluidizer in iron- and steelmaking and in the glass industry. A low viscosity and a low melting point are prime requirements for accomplishing the above. In the present study, viscosity measurements were performed. Effect of various additives, such as sand, limestone, dicalcium silicate dust, and MgO baghouse dust on the viscosity of SPL was studied. The results showed that with the addition of sand and limestone, very high fluidity of SPL melt can be obtained at significantly low temperatures. The results suggest that spent potliner mixed with additives could potentially be used as a substitute fluidizer.

Jan 1, 1999

Three complete connector assemblies and ten separate contacts were submitted to a series of tests to establish the connector permissibility and compliance with the Bureau of Mines' research Contract H 0110423. Test Procedure TPC-0100 was coordinated, and the test plan approved by the Bureau as fully complying with the intent of the contract for the low voltage, medium voltage and high voltage A.C. connectors. The components and connector assemblies have been demonstrated in testing that they meet or exceed all the requirements of the test procedure.

Jan 1, 1972

By Waugh D. M

investigations have been undertaken into the flow characteristics of mineral slurries from a number of Australian metallurgical plants including Mount Isa Mines Ltd., North Broken Hill Ltd., and Broken Hill South Ltd. Experimental equipment installed for this work included facilities for continuous recording of flow rate and pressure drop and detection of sedimentation.Although the method has subsequently been described in published literature, it is believed that the investigations included the original application of a method for correlation of the flow rate and pressure drop data. This method depends on solving by graphical methods the values of the constants k, and c in the relationship EQUATION 1 where D is pipe diameter; ?P, pressure drop; L, length; and V, mean linear velocity. Discussion of this correlation also reveals why sedimentation velocity does not necessarily vary greatly with pipe diameter.INTRODUCTIONIn order to design pumps and pipeline installations for a Newtonian fluid, measurements of the fluid's density and viscosity in any of a number of instruments are sufficient. Substitution of these values in well known equations to calculate Reynolds numbers and subsequent correlation to determine friction factors are all that is required for engineering specification.As a result of work during the last decade, particularly that of Metzner and Reed (1955) and Dodge and Metzner (1959), it is now possible to design for homogeneous non-Newtonian fluids using relatively simple instrumental measurements.These methods can sometimes be applied to thick slurries which behave as if homogeneous. However, for the...

Jan 1, 1965

By A. P. I. Popoola

Laser coatings are used for a wide variety of applications. TiB2/Ni intermetallic matrix composite coatings were fabricated on Al-substrate by a high power Rofin Sinar Nd: YAG solid-state laser. The characterization of the coatings was carried out by optical microscopy (OM), scanning electron microscopy (SEM/EDS) and X-ray Diffraction (XRD). Electrochemical study of the laser coatings in 3.65 per cent NaCl at room temperature revealed that with very high weight proportion of nickel the corrosion resistance of the coatings deteriorated due the presence of AlB10 phase. 50 wt per cent TiB2+50 wt per cent Ni laser coatings exhibited the highest corrosion resistance in test solution. Keywords Corrosion, protective film, laser surface alloying, reinforcement.

Jan 1, 2011

By Stephen Hodgson, Ken Brouwer

September 2005, Northern Dynasty Mines announced the discovery of a new, high-grade deposit at its Pebble project in southwest Alaska. The product of insightful geological investigation, Pebble East, as it is now known, is quickly growing into one of the most significant copper deposits in the world. Preliminary analysis shows it could reduce the U.S. copper supply deficit by a third. The new deposit has also altered Northern Dynasty’s view of how Pebble should be developed. This article describes the Pebble project as it is currently understood and outlines the work planned for the next several years.

Jan 1, 2007

By R. S. Olsen

Although aluminum is easily leached from calcined clay with boiling mineral acids, the presence of fines and slimes in the leached residue has hindered the application of acid leaching processes. A feed preparation method was, therefore, devised that provided a dense, smooth-surfaced, fine-grained clay. The important factors affecting feed quality were determined to be (1) crushing the raw clay to the size desired for the leaching process, (2) moistening the crushed clay with a fine mist of water while tumbling on a rotating disk, (3) drying the misted clay, and (4) calcining the dried clay at 750° C in a fluidized bed. Clay treated by this method was leached with HCI, and its residue was washed by water displacement in 4-ft-deep beds. Bed permeabilities on the order of 47 darcys or 4.6 x 10-7 cm2 were obtained with the leached residues.

Jan 1, 1983

By Sarah K. DeBono, Alan J. Monaghan, Emmanuel V. Manlapig, Gregory J. Harbort

"The Jameson Cell is a type of flotation machine in which air and pulp are brought together in a vertical tube called a downcomer. Within the downcomer the air and pulp are dispersed into a dense foam of fine bubbles, which creates a favourable environment for bubble-particle collision and subsequent collection of hydrophobic particles. The intense collection zone within the downcomer can be considered similar to the zone between the rotor and stator in mechanical flotation cells.Research into the bubble-particle collision and fluid dynamics of mechanical cells rotor-stator zone has been limited by the difficulty of achieving accurate measurements in production sized machines. With the Jameson Cell the downcomer is largely external and separated from the flotation tank, allowing ready access to the primary contacting zone for measurement and analysis.An investigation has been undertaken into the operating characteristics of the downcomer relating to bubble-particle collision. An effective mapping of the downcomer has been made through measurements of void fraction and bubble size taken across cross sections of the downcomer. Analysis of these measurements has provided an interpretation of the variations in the air and fluid dynamics, bubble size and distribution throughout the downcomer chamber."

Jan 1, 2003

By D Hill

In the Ngakuru area zeolite deposits occur in late Quaternary lacustrine vitric tuffs of the Ngakuru Formation and two of the deposits are being mined. The Ngakuru Formation overlies the Ohakuri Ignimbrite dated at c. 240 ka, and is overlain by younger alluvial sands and gravels. Individual zeolite deposits contain 50 - 80 per cent zeolite over a thickness of up to 45 m in thinly stratified vitric tuffs and are localised along NE-trending normal faults. Glass shards in the tuffs are replaced by the silica-rich zeolites mordenite and clinoptilolite. Amorphous silica (opal A), opal-CT, Kfeldspar and smectite are also present. The zeolites and other minerals are very fine grained (<10 8m), with open meshes of crystals that result in high porosities (52 - 70 per cent) in mordenite-rich tuffs. Zeolitic tuff samples typically have cation exchange capacities of 80 to 110 meq/100 g and internal surface areas of 25 - 58 m2/g, which combine to give high liquid and odour absorption capacities. The first zeolite deposit (Mangatete) was found in 1992, and this and the Twist Road deposit are worked by quarry benching into the side of hills. The zeolitic tuffs are dried and crushed to produce a variety of products including adsorbents for soaking up oil/chemical spills and animal wastes, animal feed supplements, water treatment, and sports turf and slow release fertiliser. The Ngakuru zeolite deposits formed at shallow depth (<100 m) along fault zones from reaction of glass-rich tuff beds with groundwater-diluted geothermal water during the late Quaternary, and are as young as 8500 yr BP from 14C dating of plant material in sinter associated with the Mangatete deposit.

Jan 1, 2005

By Milne J. Schmid

A program has been conducted to determine the feasibility of providing a borehole liner for Kelly Bar drilled boreholes in Southern Florida. The concept was to drill the borehole with the Kelly Bar and with it still in the borehole insert a tube which would remain in the unstable ground after withdrawl of the bar. The tube then will provide an unobstructed borehole for the charging of explosives upon completion of the drilling the shot pattern.

Jan 1, 1977

The French research institute, INERIS, requested the assistance of the CSIR?s Division of Mining Technology in developing further precautionary measures against explosions in their collieries. In response to this approach, an on-board active suppression system was adapted to meet their mining requirements. This system is used on tunnelling machines in Germany where the machine is positioned in the middle of the tunnel, which is therefore not much wider than the machine itself. With this configuration, the machine is never away from the tunnel face during the cutting cycle. As a result, the possible volume in front of the machine of combustible gas requiring suppression is less than 50 m3. In South Africa this technology has been adapted to suit a two-cut mining method which entails greater distances from the face and thus much larger volumes of methane mixtures requiring suppression. The particular configuration of the Explo-Stop® system being investigated required the suppression of possible methane ignition volumes of up to 180 m3of a 9% per volume methane/air mixture. The volume is a consequence of the large cross-sectional area of French underground workings and of the two-cut mining method used in France. In order to take the second cut in the coal seam, the machine is pulled back a maximum distance of 4 m, leaving an air pocket in which gas can accumulate. The machine-mounted system is required to effectively suppress any flame ignited by such a large accumulated volume of methane. The results of the protocol tests done at Kloppersbos showed that the system was capable of suppressing all simulated methane ignitions for the prescribed conditions. This was achieved with a temperature increase of less than a 100°C at the operator?s position and without any flame being detected at this position.

Jan 1, 2001

By Paul W. Weiblen, Louis J. Cabri, Rolando Lastra

"Preliminary tests were done to determine whether comminution by electric-pulse disaggregation, or EPD (cf. Rudashevsky et al; 1995), was more effective than using conventional crushing for Merensky Reef ore. A hand sample of the Merensky Reef was sawn in two: then one sub-sample was comminuted to – 2 mm using E-PD at the University of Minnesota, and the other sub-sample was crushed to –2 mm using a conventional jaw crusher at CANMET.The products of the electric-pulse disaggregation and jaw crusher were fractionated by sieving and by a separation using a heavy liquid with a specific gravity of 3.3, because the proportion of platinum-group minerals (PGM) and sulphides to silicate minerals is very low. Thus, four mineral separates were produced: –2000 + 833 µm, -833 +208 µm, -208-µm float and -208-µm sink. All the mineral separates were studied by image analysis (Lastra et al; 1998). The main objective was to determine the liberation of gangue (silicate minerals), chromite, pyrrhotite, chalcopyrite, pentlandite and PGM. In the case of the PGM, a specific image analysis program was written to search and measure these minerals."

Jan 1, 2003

By Robert F. Randolph, Christa L. Themann, Efrem R. Reeves, Thais C. Morata, Babette L. Verbsky, David C. Byrne

Objective: Workers with hearing loss face special problems, especially when working in noise. How­ever, conventional hearing conservation practices do not distinguish between workers with normal hearing versus impaired hearing. This study col­lected information from workers with self-reported noise exposure and hearing loss, supervisors of such workers, and hearing conservation program managers through focus groups and in-depth inter­views to evaluate their perspectives on the impact of hearing loss on safety and job performance, the use of hearing protection, and information needed to appropriately manage hearing-impaired workers who work in noisy environments. Results: Concerns about working in noise with a hearing loss could be grouped into the following 10 categories: impact on job performance, impact on job safety, impaired ability to hear warning signals, impaired ability to monitor equipment, interfer­ence with communication, stress and/or fatigue, impaired communication caused by hearing protec­tor use, reduced ability to monitor the environment as the result of hearing protector use, concerns about future quality of life, and concerns about future employability. Mostly, there was an agree­ment between the perceptions of workers, supervi­sors, and hearing conservation program managers regarding difficulties associated with hearing loss and consequent needs. These findings suggest that noise-exposed workers with hearing loss face many of the same problems reported in the literature by noise-exposed workers with normal hearing, with additional concerns primarily about job safety as the result of a reduced ability to hear environmental sounds, warning signals, and so forth. Conclusions: The study outlines potential chal­lenges regarding job safety and hearing conserva­tion practices for noise-exposed, hearing-impaired workers. Awareness of these issues is a necessary first step toward providing appropriate protective measures for noise-exposed, hearing-impaired workers. Of the 19 million adults in the United States with some degree of hearing trouble, nearly half are currently employed in the workforce (NCHS, 1994). More than 30 million US workers are exposed to hazardous noise levels, and noise-induced hearing loss is the most common occupational disease in the United States (NIOSH, 1996). Many workers incur their hearing losses during the first 5 to 10 yrs of employment (Rosler, 1994; Ward et al., 2000) and subsequently work the rest of their careers in an environment where noise and hearing loss interact to impair their ability to hear communication and other important signals. Workers with hearing loss who are exposed to hazardous noise levels present a dilemma to hearing loss preventionists. On the one hand, it is of great importance to ensure that their residual hearing is protected from the damaging effects of the noise to which they are exposed. On the other hand, how­ever, traditional hearing protectors serve to further “deafen” such workers, making communication more difficult and impairing the detection of environmen­tal sounds and warning signals. These workers have special needs that must be addressed. However, conventional hearing conservation practices do not distinguish between workers with normal versus impaired hearing; and, to date, no governmental or professional organization has developed specific guidelines or policies concerning the accommodation of noise-exposed, hearing-impaired workers. Some research regarding noise-exposed, hearing-impaired workers has been completed. These studies have primarily focused on three areas: (a) speech intelligibility in noise versus quiet, with and without various types of hearing protection devices (Abel et al., 1982; Abel et al., 1993; Abel & Spencer, 1997; Rink, 1979; Suter, 1989); (b) signal detection and localization under similar conditions (Abel et al., 1993; Abel et al., 1985; Abel & Hay, 1996); and (c) the use of hearing aids as hearing protectors (Berger, 1986; Dolan & Maurer, 1996; Hétu et al., 1992; Hétu et al., 1993). Research in these three areas has provided an initial framework for development of a management para­digm for these workers. However, each of these studies addressed a very specific research question, examining