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By John P. Weir

The coal industry is ever changing. This paper discusses some of the problems which must be faced and the projected economic effects. Challenges include a relatively mature technology, a resource base which has deteriorated significantly in some areas, rapidly escalating freight rates, and a constantly changing regulatory environment, wherein reduced sulfur emissions will probably be required.

Jan 1, 1984

By S. K. Kawatra, M. T. Rusesky, T. C. Eisele

An on-line monitoring system for apparent slurry viscosity has been developed at Michigan Technological University. It utilizes a vibrating sphere viscometer in conjunction with a special slurry presentation system to reduce particle settling and turbulence effects. It has proven to give accurate, reproducible results in an on-line hydrocyclone installation. Its performance shows that it can be an effective instrument on an industrial scale, particularly in grinding circuits. Development of the sensor and the importance of rheology in grinding are also discussed.

Jan 1, 1992

By A. J. Surtees, M. P. Evans

This paper discusses the development and application of sophisticated monitoring equipment used to measure the operating parameters of conveyor systems. With the radical reduction in price of computer hard- ware and software during the last decade and an associated increase in memory capacity, the concept of continuous conveyor monitor is now a reality. With this tool, the various problems normally encountered in large conveyor installations can now be avoided at an early stage. • The four main areas of application are: • Design verification • Hand-over certification • Preventative maintenance and increase of system availability Failure analysis The paper introduces the techniques used and gives examples where the service has been used.

Jan 1, 1996

By T. Shungu, N. Vermaut

The various copper-cobalt ores mined by Gecamines, together with typical plant applications and results, are briefly described. Intensive laboratory investigations have been undertaken in recent years to improve the metallurgical performances of the various concentrators. As a result of these tests, it was shown that the flotation of the siliceous oxide ores could be improved by increasing the efficiency of the palm oil collector (energetic conditioning, chemical emulsifier, petroleum sulfonate addition) and by varying the froth depth in the cells. A new flowsheet incorporating these modifications and a regrinding stage has been approved for the rehabilitation of the Kolwezi concentrator. For what affects dolomitic oxide ores, hydroxamates were tested as secondary collectors and, based on successful laboratory results, plant trials were run but failed due to excessive frothing. In other plant tests, xanthates were replaced by a xanthate- fatty acid mixture; plant trials over more than one year proved successful for copper, but not for cobalt. Mercaptans were tested as secondary collectors for the sulfides flotation from sulfide or mixed oxide-sulfide ores; laboratory results proved successful but, to date, no plant test has been run.

Jan 1, 1987

By J. M. Keane

Critical to successful dump and heap leaching for copper is an adequate testing program for evaluation of the applicable parameters. This paper deals with testing methods to establish best conditions for dump and heap leaching of copper so that commercial operations can proceed on a rational basis. Discussion is also offered of ore occurrences suitable for dump and heap leaching.

Jan 1, 1985

By D. L. Purcell, B. T. McClure, J. McDonald

The U.S. Bureau of Mines has completed a laboratory evaluation of exhaust emissions from a diesel engine using an oxygenated diesel fuel. The fuels tested were soy methyl esters in a neat (100%) form and low sulfur, petroleum number 2 diesel fuel (D2). The engine tested was a Caterpillar 3304, indirect injection, naturally aspirated, 75 kW, diesel engine that is typical of engines used in underground mining applications. The objective was to determine the extent to which oxygenated fuels, such as methyl esters, reduce diesel particulate matter (DPM), and their influence on upon gaseous emissions such as total hydrocarbons, CO, NOx, NO2, formaldehyde, and other exhaust emissions. Heavy- and light-duty transient tests were used to simulate load cycles typical of mine applications. The soy methyl ester fuel produced greater amounts of volatile DPM (organic material) but much less nonvolatile DPM (carbon soot) for overall DPM reductions. A diesel oxidation catalyst (DOC) typical of the type commonly used in metal and nonmetal mines was tested with both fuels. The DOC further reduced the volatile and total DPM when used with the soy methyl esters, but increased the total DPM for D2 due to sulfate formation. The soy methyl ester fuel reduced CO and hydrocarbon, and NOx emissions. The DOC further reduced CO and hydrocarbon emissions.

Jan 1, 1995

By J. Drelich, J. Pletka

Lost foam casting is a process in which a polymeric material is formed into the shape of the part to be cast. Parts that are more complex are fabricated by simply gluing several patterns together. The pattern is then coated with a refractory material consisting of a mineral mixture and binders. Finally, hot metal is poured into the pattern, evaporating the expanded polystyrene and taking the shape of the coating shell. Prior to casting, a significant number of the patterns are damaged and inevitably landfilled. In this study, a process was developed for the recovery of expanded polystyrene from the coating and glue contaminants. The process consists of shredding, impact comminution, size classification and pneumatic separation. It is successful in separating up to 97% of the contaminants, while recovering 95% of the polystyrene. Key words: Casting, Lost foam process, Expanded polystyrene recovery

Jan 1, 2003

By Laura J. Carroll, Gordon A. Goldsmith

Experts, like many of the speakers at the SME Annual Conference, are frequently called upon by lawyers to assist them in litigation. Due to the technical nature of many cases, the testimony of an expert with knowledge and experience in a particular field is necessary to help a judge or jury understand and decide certain issues. Environmental litigation is no exception. Experts routinely are called upon to offer testimony to establish the existence of contamination and its source, as well as the potential health and environmental risks associated with the contaminants. This article will briefly discuss the factors courts apply to determine whether to admit expert testimony after the recent Supreme Court decision in Daubert v. Memell Dow Pharm., Inc., 509 U.S. 579 (1993). The Court's decision in Daubert overruled a long-standing test that had based the admissibility of scientific evidence on its "general acceptance" in the field in issue. Next, the article will discuss in general terms what a party must do to "link a particular defendant's conduct to the contamination involved in order to recover from that defendant. This link, known as causation, varies depending upon the type of claim being asserted. Expert witnesses are used extensively to help establish causation. JUNK SCIENCE OR GOOD SCIENCE- HOW DOES A COURT DETERMINE WHAT TO LET IN A frequent complaint in litigation involving technical or scientific issues is that one party or another is trying to use so-called "junk science" to prove its case. While some expert testimony might be so clearly lacking in support or so "off the wall" that a court can easily determine to exclude it, other testimony, especially testimony on the "cutting edge," is much more problematic. In 1923, the District of Columbia Circuit Court of Appeals decided the case of Frye v. United States, 293 E 1013 (1923). In deciding whether to admit certain expert testimony, the court in Frye stated that while a court will "go a long way in admitting expert testimony deduced from a well-recognized scientific

Jan 1, 1998

By Gerald V. Jergensen, Edward J. Samuel

Slurry system are the principal method for storage and transportation of solids within and between concentration operations In a mineral processing plant. A slurry 1s a mixture of solid particles In water, or a chemical solution, that behaves like a liquid. The design of slurry transportation systems is generally analagous to pumping and piping water, but with a few notable exceptions: • The interaction of particle on particle affects slurry transport. • Particles often interact with the fluid, particularly when chemicals have been added to the system. • Particles have a frustrating tendency to settle from the slurry suspension, especially into locations not considered In the design. • Solids have an affinity for wetted surf aces and tend to wear them away. Slurry transportation systems Include a number of separate components, each requiring special design considerations. A systematic evaluation of each component of a slurry transfer system will help overlooking the small details that could cause operational headaches. Most slurry transport systems include: • A receiving sump or tank that provides for mixing and/or momentary storage of slurry. • A driving force.. by a pump, atmospheric pressure or gravity. • A suitable conduit for transportation.. pipes or launders. • A delivery objective.. another sump or process vessel, or distribution system to several process points. • A control strategy and design to regulate the transfer operation. The design of the slurry transportation system normally evolves through the following steps: • Finalizing the process flowsheet and establishing the weights and volumes to be handled. • Identifying and characterizing the various process fluids and slurries. • Defining critical and minimum transport velocities of fluids. • Selecting a pipe diameter (or dimensions and gradient) and

Jan 1, 1986

By A. D. Trujillo, R. D. Wunder

The Chino Mines Co., a Kennecott- Mitsubishi partnership, located in Hurley, NM, recently completed a $405 million modernization of its mine, concentrator, and smelter facilities. The mine/concentrator modernization commenced in 1980, and the smelter modernization began during 1982. Modernization of the mine and concentrator facilities involved increasing the mining rate from 98 kt/d (108,000 stpd) to 152.2 kt/d (167,800 stpd). Ore mining was designed to increase production from 20.2 kt/d (22,300 stpd) to 34 kt/d (37,500 stpd). A new concentrator was con- structed near the mine using semiautogenous grinding. The new smelter uses the INCO flash smelting process, increasing capacity by 40.8 kt/a (45,000 stpy) to 99.8 kt/a (110,000 stpy) of saleable copper.

Jan 1, 1988

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 A. Giardino, Leonard C. Marraccini

This paper surveys noise levels, noise exposure patterns, and frequency spectra found in the mining environment; the effects of mining noise on the working population; and the quantification of hearing loss in the coal mining industry. Federal mining noise regulations and the present state of the industry, with respect to noise control technology, are discussed. Examples of proven noise controls for mining are included along with measured noise reductions.

Jan 1, 1986

By Joe Scheuering, Don Poulter, John Trirnble

Closure of the Grey Eagle Mine tailings impoundment is an example of closing a "wet" tailings impoundment at the cessation of milling operations. This paper presents a summary of tailings cover design and construction, tailings deposition sequences to facilitate closure, construction schedules, costs, and post-closure monitoring. Permit requirements which influenced the design and construction of the tailings are summarized. The performance of the cover and post-closure monitoring issues are also discussed.

Jan 1, 1995

By N. P. Reddy, Y. J. Wang

Stall or aerodynamic stall of axial flow fans has long been recognized as an important operational problem in mine ventilation. To develop a technique for characterizing fan stall in multiple fan ventilation networks, a research project was initiated through the Generic Mineral Technology Center for Mine Systems Design and Ground Control. Considering that fan stall is related to multiple operating points, this paper discusses a numerical model for multiple fan ventilation networks, and numerical methods for solving multiple networks solutions. It is hoped that the results of this project will lead to an innovative method of ventilation network analysis and simulation, thus preventing stall.

Jan 1, 1993

Stratabound uranium deposits consist generally of two comingled geologic and statistical populations. Barren zones, usually having radiometric assays too low for recording on digitized logs, comprise a large portion of a mineralized stratum. In between are mineralized zones; where the grades are distributed essentially lognormally. Estimation of open-pit ore reserves requires the prediction of the tonnages of selective mining units (the smallest mined volume which may be segregated as ore or waste) and their grades within panels of convenient size for open pit planning and economic analysis. The proportionate tonnage of mineralized selective mining units within each panel can be predicted by kriging an an indicator function assigned to each composite (1 if mineralized, 0 if barren). Next, using logarithms of mineralized assays, the conditional lognormal distribution of grades of mineralized selective mining units can be found. Using this distribution and the krigedestimate of the probability a selective mining unit is mineralized, the grade and tonnage of selective- mining units above any cutoff can be predicted. A case study illustrating this two- step procedure is presented for the Imouraren uranium deposit located in the Republic of Niger. Using cross validation, the estimation procedures were checked and were shown to be adequately accurate for mine planning purposes.

Jan 1, 1979

By Frank Sames

A recently developed model is used as a tool to optimize blast designs based on the continuing combination of full scale blast assessment and performance prediction. The use of this tool has allowed to evaluate present blasting practices and proposed designs through a better under-standing of the influence of the various blast parameters. The empirical model has a modular structure covering all aspects of blast performance including 30 fragmentation, potential rock damage and 30 muckpile profile prediction. The modules are assisted by a terrain model which is compatible to most mine mapping systems, and a blast design editor. The evaluation is summarized in a blast management module. Various studies have recently been undertaken using the model to qualify and improve blast designs with respect to wall stability, optimized fragmentation and muckpile distribution, as well as to the control of the environmental effects such as blast vibration and airblast overpressure. To verify the predictions of the modeling, full scale blast assessment techniques were used to qualify blast geometry, explosives and initiation performance, rock movement, muckpile distribution, near- and far-field vibration levels and airblast ovepressures. The model provides a tool to gain an improved understanding of blasting and blast control. The modeling results are presented in a visual form which allows simple comparisons of proposed blast designs. Additionally, the model can be used for detailed analysis and blast management.

Jan 1, 1996

By Wilhelm J. Kogelmann

The concept and operation of novel shaft sinking systems utilizing roadheader-type cutter booms, including mucking, conveying, and hoisting installations, are described. Selection criteria, performance data, and economic considerations for various shaft excavators are presented. Various applications of this low-cost and flexible system for civil engineering and mining projects will be discussed. The cutter booms can work in both soft ground and competent rock. Furthermore, the novel excavator can operate in ground stabilized by grouting, cementing, and freezing. The flexible cutting system can be used both for excavation of shafts, foundation pits, slopes, and for tunneling (drifting).

Jan 1, 1989

By J. M. Mutmansky, Y. J. Wang

The method usually used to predict the direction of flow in a connecting airway is to conduct a survey of the two existing nodes to be connected by the new pressure airway. It is then assumed that the air will flow from the node with the measured higher pressure to the node with measured lower pressure. This paper examines this direction-of-flow problem using properties of the system characteristic curve for a two-terminal network and specifies some conditions that will ensure that the air will flow in the direction anticipated. It was concluded that the only requirement is that all characteristic curves of the fans in the network should be strictly decreasing. Five numerical examples illustrate some important proper- ties of the direction-of-flow problem.

Jan 1, 2000

By R. F. Al-Fariss

The phosphoric acid industry is expected to develop in Saudi Arabia in the near future. There are three main reasons for expecting this: the discovery of phosphate deposits in the Sirhan-Turayf region, the construction of phosphate fertilizer facilities of the TSP, DAP and NPK plants on the east coast of the country, and the availability of an ample amount of sulfur As a by-product from the petrochemical industries. This study is a part of the research work performed in the chemical engineering department At King Saud University to evaluate the Saudi phosphate rocks for the wet process phosphoric Acid production and to test different flotation methods for the carbonate rich phosphate rock In a laboratory scale flotation cell. Experimental results for the above tests, as well as Beneficiation by calcination, are presented.

Jan 1, 1993

By J. G. Groppo, J. G. Justice, B. K. Parekh

Removal of particulates and/or metal ions from mineral/coal processing waste water is a necessity from the environmental point of view. This paper describes application of a novel AC- electrocoagulation technique to remove the particulates as well as metal ions using AC power. A series of laboratory tests conducted on a stable black water sample obtained from a sub-bitminous coal operation provided a clear supernatant (-10 NTU) from the suspension. The process also shows promise in removal of up to 90 percent of phosphate ions and other metal ions (copper and nickel) from solution. A preliminary economic evaluation of the process will also be included.

Jan 1, 1992