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By Kenneth A. Rogers, Richard F. Hill

Introduction A number of processes for deriving more convenient liquid and gaseous fuels from coal are commercially available or in final stages of development. Generally, synfuels from coal processes have efficiencies ranging from 50 to 70%. Considerable engineering design and development work are necessary to bring forth commercial plants using the various technologies-but technological breakthroughs are not expected or needed. Gasification While a variety of solids handling, gas contacting, and gas quality upgrading techniques may be employed in the various gasification processes, the primary goal is the same-to convert a sulfur-containing solid to an essentially sulfur-free gaseous product. The gaseous product may be a mixture of hydrogen and carbon monoxide with nitrogen. Definitions are not rigorous, but high-Btu gas is generally over 900 Btu/scf(33 534 kJ/m3) and low-Btu gas is generally below 350 Btu/scf(13 041 kJ/m3). Medium or intermediate gas falls between these values. High-Btu production is more difficult, as it requires additional upgrading of a low- or intermediate-Btu gas stream to produce a commercially acceptable product. The carbon/ hydrogen ratio is adjusted either by rejecting a portion of the carbon, increasing the hydrogen, or a combination of both. The chemical processing steps include production processing gas containing carbon oxides and hydrogen by the reaction of carbon and steam (gasification); reaction of hydrogen and coal to form methane (a hydrogasification process); reaction of hydrogen and carbon monoxide to produce methane (methanation); and the removal of impurities. The gasification processes share a number of common techniques. The coal received at the plant site must be further cleaned and crushed or ground before it can enter the gasifier. Conventional cleaning methods are used to remove extraneous materials such as metal, rocks, etc. For some processes the coal must be finely ground so it may be fluidized or entrained in a flowing gas stream. For other processes crushing and sizing only are required. Agglomerating coals may be pretreated by heating, mild oxidation with air, or other procedures to assure smooth gasifier operation and to avoid reactor plugging. Nonagglomerating coals Such as lignite and subbituminous coal normally do not require pretreatment. Feeding a solid material such as coal to a higher pressure reactor is a difficult task. Dry feeders using a series of pressurized lock hoppers, or wet systems in which a slurry is pumped into the reactor, are used. The gasification step is the heart of the process. Here, the solid feed material is contacted with synthesis gas (carbon monoxide and hydrogen). The coal is devolatilized and a portion of the fixed carbon converted to methane. The gas-solids contacting methods used include fixed beds, fluidized beds, moving beds, entrained beds, and free-fall systems. The gasification process, overall, is endothermic and the heat required to maintain reaction rates is usually supplied by burning a portion of the coal feed. External heat sources such as electric resistance heating, molten salt or solid heat carriers, and the introduction of a hot hydrogen stream also have been tested. Following the gasification step the particulate materials and heavy hydrocarbons contained in the reactor effluent are removed by a water quench and solids separation system. If low-Btu gas or synthesis gas is the desired product, the raw gas is scrubbed to remove carbon dioxide and sulfur compounds and then is used directly. However, if high-Btu gas is desired, methanation is necessary. In most gasification processes, the hydrogen content of the gasifier

Jan 2, 1980

By James L. Parks

This paper describes improvements in SAG and AG mill liner designs and their cumulative effect on wear life and mill availability. Routine procedures used by many SAG and AG mill operators to improve liner life are reviewed. Guidelines are provided for estimating the time required to replace worn liners along with practical methods to reduce downtime for liner replacement. Finally, the effects of mill operating conditions on liner wear life and breakage are considered.

Jan 1, 1998

By J. A. Herbst, L. B. Hales, R. A. Ynchausti

Industrial application, theoretical discussion and technical research programs continue to stimulate acceptance of column flotation. Numerous authors have published model, parameter and application studies discussing advantages and problems which are associated with this minerals processing technique. This paper dispells the myth of the self-controlling column while focusing on the problems and opportunities which are inherent in the computer control of a column flotation cell.

Jan 1, 1988

By T. Tamagawa, I. Iwasaki, N. X. Fu, M. Kobayashi

A three-stage fluidizing-bed process consisting of chlorination, selective oxidation and sulfur chloride conversion was tested for processing chalcopyrite concentrate. It was found that the use of excess oxygen was essential for the stable operation of the oxidation reactor. The excess-oxygen gas inevitably causes the oxidation of the sulfide concentrate in the chlorination and sulfur chloride conversion reactors. A new flowsheet is proposed to separate the chlorination and selective oxidation steps with separate flow paths of the fluidizing gases, thereby, preventing the passage of excess-oxygen gas in the chlorination and sulfur chloride conversion reactors. The feasibility of the proposed flowsheet was demonstrated in a laboratoryscale fiuidizing bed setup.

Jan 1, 2002

By R. V. Ramani, R. Srikanth

A three-part study was conducted to relate the dust generation propensity of a coal sample, defined here as the dust generation rate (grams of dust generated per tonne of coal broken), to its characteristics, in order to rank coal seams according to their respirable dust generation potential. In this paper, the results of a single breakage study on a variety of coal samples encompassing all coal ranks, and samples from operating mines are discussed. Further, where data are available, the primary dust generation rates of coal samples collected from underground coal mines are compared with the in-mine dust generation rates. The results of this analysis are then used to apply the results of this study to longwall face ventilation design. Vitrinite reflectance, and level of organic metamorphism are highly correlated with primary respirable dust generation rates of bituminous coal samples. The dust generation rates in underground coal mines are an order of magnitude higher than the primary dust generation rates in the laboratory. Depending on the type of coal, production rates, and dust control procedures, the air quantity required for airborne dust control can vary significantly. The air quantities on some high production longwalls are approaching the limits beyond which it may not be possible to reduce ambient ARD concentrations to less than 2 mg/m3 by dilution ventilation alone. In these cases, the miner's exposure should be controlled through the use of personal protective de- vices and administrative practices.

Jan 1, 1997

By L. Xu, R. Bhaskar

While a NIOSH accepted procedure exists for determination of quartz in the respirable dust samples from coal mines, no specific procedure has been defined for quartz determination in bulk samples. In this study, the effect of particle size on the estimation of quartz using the infrared technique was evaluated. Several laboratory tests were performed to determine the dependence of the infrared absorbance peak height on the different sizes of quartz particles. The significant dependence observed between quartz particle size and the measured peak height indicates the potential for erroneous interpretation of the quartz in bulk samples depending on how the samples are prepared. A procedure to reduce the effect of size in the determination of the quartz content is suggested.

Jan 1, 1994

Many organisations, including those in the resources industry have Board-level endorsed principles on sustainability. A key challenge, however, is how to systematically integrate these high-level principles into the design and operation of mineral processing plants. In an effort to meet this challenge the Sustainable Operations framework, called SUSOP®, was conceived and developed through the Corporative Research Centre for Sustainable Resource Processing (CSRP) in Australia. Somewhat analogous to HAZOP (Hazard and Operability Studies) which is well entrenched in the resources industry, the key aim of SUSOP® is to produce a holistic, systematic and rigorous methodology for identifying and assessing sustainability opportunities and risks. This paper argues the need for such a sustainability framework, presents the key elements of SUSOP®, highlights how case studies enhanced its development and articulates the reasons why such a framework will have growing importance into the future.

Jan 1, 2011

By H. M. Lima, P. Wathern

There are many different words to describe mine closure, including rehabilitation, reclamation, restoration and decommissioning. Closing mining operations, mainly open pit mines, has required resolution of numerous issues. Mine closure plans involve environmental-protection issues, regulatory issues and community issues. The obvious, and often most expensive of them, is the physical rehabilitation of the disturbances and the elimination of long-term commitments and maintenance. This paper outlines mine closure planning and its important component, mine-site rehabilitation. Community consultation and involvement are also referred to as an important component of the mine-closure plans, which are required to ensure satisfactory mine site rehabilitation. Considerations of socioeconomic impact of mine closure and long-term responsibilities are presented.

Jan 1, 2000

By A. W. Mitchell

Mining of a bedded barite deposit exposed highly pyritic siliceous sediments which have weathered and degraded subsurface and surface waters. The ph, sulfate, and total dissolved solids are the most seriously affected parameters. Several solutions were tried and eventually horizontal holes were drilled into the mine wall to draw down the water table and decrease the movement of groundwater through oxidizing zones opened up by the mining operation. Areas of surface disturbance were capped with layers of soil, bentonite, and gravel to decrease the infiltration of water into the disturbed areas. These actions have begun to decrease sulfate and total dissolved solids concentrations and increase ph values.

Jan 1, 1987

By William S. Eaton

Managing a mine or mineral processing operation in today's environment presents many unique challenges to mining companies. In recent years, headlines around the world have publicized major incidents such as those associated with the Marcopper Mine in the Philippines, the cyanide release in Guyana from the Omai gold mine and numerous other mishaps associated with mining. These notable upsets were due to engineered system failures, either during normal operations or as a result of uncontrollable events. There fore, many mining firms are attempting to assess their overall risks and establish some priority for expenditure of limited operational and environmental budgets. Failure of an engineered component can have dire operational consequences that affect profitability until repair or replacement can be completed. In addition, there may be significant environmental consequences associated with the engineered system failure. This, too, may affect profitability for an extended time or even the viability of an operation. An engineered risk assessment (ERA) can support a mining company's efforts to cost effectively manage environmental risks associated with the operation of its facilities. The ERA approach also provides information about the current condition of engineered systems. This ERA approach provides a systematic review of the risks of an engineered system failure and the possible associated environmental consequences at mining company facilities. This approach has been successfully applied to many industries and types of engineered systems (Barneich et al, 1996; Whitman, 1984; Power and Tomkins, 1974; Keeney, Nair, and Kulkarni, 1979). This approach evaluates all mining and mineral processing facilities located at a single site and compares them with similar facilities located at multiple mine sites. The ERA approach has been applied to a mining, milling, smelting, leaching and refining operations. These assessments can be part of a comprehensive environmental program to aid in the recognition and cost effective management of the potential environmental risks associated with the operation of facilities. ERA results support plan-

Jan 1, 1997

By B. Ni, J. D. Robertson

A new radioactive tracer method for the measurement of airflow in inaccessible airways was developed. The method can be used in situations where studies of the mine-ventilation system are not possible using conventional flowmeters (anemometers). The method was tested in the ventilation laboratory at the University of Kentucky and in the US Bureau of Mines Experimental Underground Coal Mine and was utilized in leakage, dilution and flow-velocity measurements.

Jan 1, 1998

By Morris Loshinsky, George Ziegler

NEW ROUTES - 63rd STREET CROSSTOWN The New Route construction along East 63rd Street in Manhattan began in 1969 with the East River tunnel connecting Manhattan and Queens. The 63rd Street Line, once in Queens, is planned to connect to another new route called the Queens By Pass or Super Express (See Exhibit 1) which would connect to the Queens Boulevard Line at Forest Hills. The purpose of the Queens By Pass was to alleviate subway congestion to and from the Borough of Queens, whose population had rapidly expanded during and after World War II. The existing Queens Boulevard subway lines (the "E" and the "F" trains) are almost filled to capacity at their terminal stations with passengers from Long Island. Passengers boarding trains enroute from the local Queens stations have difficulty boarding crowded trains, and, at times, cannot board the trains. The New Routes, thus, were to give additional train capacity into Manhattan and thereby relieve the crowded conditions along the Queens Boulevard corridor. PROFILE - METHOD OF CONSTRUCTION The portion of the New Route passing east-west under East 63rd Street on Manhattan (See Exhibit 2) had to snake beneath intersecting structures running north and south, such as the Con Rail tracks below Park Avenue and the 80 ft deep Lexington Avenue Express track structure along Lexington Avenue. Further, the Lexington Avenue Local tracks are in a separate structure which has a high profile close to the street surface. Therefore the 63rd

Jan 1, 1981

By Nes?e Çelebi

It has never been easy to finance within mining sector. Leasing may be an alternative source of finance for mining investments. Leasing is acquiring the right of usage for an asset for a definite period of time without having the ownership of it. In this study, a model for analyzing the lease financing opportunities for mining investments under risk and suitable for establishing a satisfactory leasing policy for both lessee and lessor is developed. Using the model, it is possible to obtain an expected equilibrium lease amount acceptable by both lessor and lessee and also the expected range of the equilibrium lease amount as a decision tool. First the existing leasing policies are mentioned, then the developed model is described. A case study is presented to illustrate the use of the model in establishing a leasing policy. In conclusion, the usefulness of the model is discussed.

Jan 1, 1992

By C. L. Karr, D. E. Goldberg

This paper considers optimization of the design and operation of an air-injected hydrocyclone (AIHC) via a genetic algorithm (CAI. The AIHC is a mineral separating device, developed by the U.S. Bureau of Mines, that combines the selectivity of flotation with the capacity and simplicity of hydrocyclones. GA's are search procedures based on the mechanics of natural genetics. Computer results demonstrate the ability of a GA to rapidly locate design and operating parameters that improve AIHC performance. A computer model of the GA-designed AIHC predicts improved recovery over that currently being obtained with an AIHC in operation at the U.S. Bureau of Mines Tuscaloosa Research Center.

Jan 1, 1990

By S. K. Kawatra, A. K. Bakshi

Mineral suspensions in water show Newtonian flow properties at low percent solids. However, this changes to a non-Newtonian regime as the pet-cent solids increases. For Newtonian fluids, viscosity is independent of shear rate, hut, for non-Newtonian fluids, viscosity varies with shear rate. Therefore, if the slurry is non-Newtonian, attempting to measure the viscosity at a shear rate different from the shear rate experienced by the fluid within the process is futile. This is especially true for a hydrocyclone, where the rate of shear is different at different points within the hydrocyclone. In this case, it is very important to determine the flow type of the suspension before attempting to establish any correlation between the viscosity and the process efficiency. A new technique to distinguish such changes inflow type was developed. This involves two viscometers: a coaxial cylinder-type viscometer that measures apparent viscosity at low shear rates and a vibrating sphere-type viscometer that measures the apparent viscosity at high shear rates. For each of these instruments, special precautions were taken to allow, for the measurement of the viscosity of rapidly settling mineral suspensions. Because the vibrating sphere viscometer is operated at a much higher shear rate than the rotating viscometer, the two instruments together could determine the shear-rate dependency of the viscosity. Ground silica (80% passing 65 µm) in water was used to prepare slurries at concentrations ranging from 10% to 70% (by weight) solids. The viscosity of each slurry sample was measured simultaneously by both viscometers, and the results were compared. With this technique, it was found that all of the silica-slurry samples tested were in the Newtonian flow regime for up to 70% (by weight) solids. Methocel and Cellosize polymer solutions showed clear non-Newtonian behavior using this technique. This confirmed that non-Newtonian behavior of the silica slurries, if present, would have been detected by this arrangement.

Jan 1, 1997

By K. Nagata, T. Kawashima, S. Tejima

The expanding volume of maritime coal transportation is intensifying the problems concerning large vessel service, port construction, trans-shipment, and environmental control. The major problem is the shipment of coal. Customary methods for bulk transfer must be improved and new systems developed. Slurry unloading has a key role in the new systems. This report reviews progress in slurry transportation research that has been done in Japan since the 1960s, when large-scale experiments for domestic transportation were done. Experiments on the effects of vibration on the slurry cargo and on reslurrying are focused on.

Jan 1, 1987

By H. Douglas Dahl

In order to provide a reference framework for discussing the applicability of drilling technology to shaft construction in coal mining ventures, it is meaningful to review the history and nature of United States coal mines relative to shafting. Coal mining in the United States is characterized by shallow depths relative to most of the coal mining world. While the trend is toward deeper and deeper mines, many new mines have shaft depth less than 800 feet, and a large number of operating mines are drift or outcrop mines utilizing shafts for ventilation and portals. In the past, shafts of 200-300 feet have been commonly constructed. The use of conventionally sunk shafts at present and in the past is due in part to the shallow shaft length required, favoring conventionally sunk shafts. Another factor is that large shafts are required for multipurpose and production shafts. A third has been the practice of utilizing shaft construction contractors who had been until recently very competitive with raise drilled shafts at shallow to moderate depths. Recently, however, the costs of conventionally sunk shafts have skyrocketed. Too, more shafts are being required. Several factors are responsible among which are: (1) The increasing depth of shaft required for new mines and for shafts in advance of old mines. This significantly affects unit costs, e.g. $/yd3,of conventionally sunk shafts. Moreover, more gas is encountered in the shaft sinking operation.

Jan 1, 1976

By E. L. Bohnet

The purpose of this paper is to translate a mining company's "Corporate Objectives" into usable and practical guidelines for long term mine design and production scheduling. These guidelines are required to ensure that both operating and development properties are designed and economically ranked on the same basis, and with the "current" Corporate Objectives in mind. Secondly, if both management and mining engineers have a better understanding of the cause and effect of corporate policies, then penalties and risks associated with various Corporate Objectives can be put into better perspective for management. Corporate Objectives, relative to usable guidelines for either short and/or long term mine planning, could be defined as one or more of the following four objectives: 1) Maximize the recovery of the economic portion of the defined geologic resources, and hence, maximize total non-discounted project cash flows and profits (most common approach in mine design), 2) Maximize the Net Present Value (NPV) of the after-tax cash flows from each existing or proposed project, either on an individual basis or in concert with other projects, including downstream processing facilities (primary method used to judge relative investment merit of a proposed development or operating concept), 3) Limit short and long term capital expenditures to a defined ceiling, 4) Maximize product output for the existing facilities in the short term, or conversely, keep commodity production at a constant level for a series of years.

Jan 1, 1994

By Y. M. Jiang, D. W. Park

Longwall faces can move at high advancing rates, but many geological variations can cause unexpected instabilities and production losses. The rapid movement makes it necessary to evaluate different geologic conditions in the rock mass as fast as possible to assess their effects on the longwall face and shields. It is believed that prompt awareness of geologic conditions is the key to preventing instability at a longwall face. This paper introduces the application of fuzzy set theory for characterizing and evaluating roof conditions. Real-time monitored data coupled with fuzzy set analysis provides valuable information, such as shield leg pressure, developing load on shields, intervals of periodic weighting and the ratio of developing loads during periodic to normal times.

Jan 1, 1998

By Mark L. Munsell

In recent years, miners have tried many approaches to maintenance such as: - Highly sophisticated computerized programs. - large planning groups designed to preplan and schedule work. - Contract maintenance. - Break down maintenance. Each of these approaches has faced the added constraints: - High replacement cost of equipment necessitating longer useful equipment life - management?s increased scrutiny of all indirect costs such as maintenance. Faced with these factors, what system of maintenance control is right? After visiting many properties recently, it appears there is no right system. Maintenance programs need to be tailored to the people and production constraints that occur at an individual property.

Jan 1, 1976