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By R. C. Klimpel

Size reduction of material in aqueous pulps by the use of tumbling media overflow discharge mills is an important and common unit operation in industry. There also has been extensive attention given in recent decades on developing a more fundamental understanding of the breakage processes involved, especially in ball mills. These studies have mostly emphasized the use of size-mass balance or population balance approaches for quantifying the analysis and design of size reduction circuits, ego Austin, et al (1984).

Jan 1, 1989

By R. Pinksen

The IOC Mining and Operations Departments expressed an interest in reducing the amount of oversize material (>1.0 m x 1.0 m x 1.0 m; 39 inches x 39 inches x 39 inches) being produced and its subsequent downstream effects including in-pit sorting and reduction, damage to mobile equipment, and significant delays in the loading pockets and the primary crushers. To achieve this goal an oversize reduction project was undertaken by the mine and to date has significantly improved upon baseline measures. One key approach used to reduce the amount of oversize was the implementation of thicker emulsion. The introduction of a thicker emulsion provided more resistance to the forces created by dynamic water and reduces the infiltration of the emulsion into the cracks and fissures of the rockmass. Reduced amounts of oversize and more consistent fragmentation throughout the muckpiles has been a result. Additionally, a significant reduction in nitrates leached into the mine water discharge has been realized. To determine the effectiveness of the oversize reduction project, IOC used a of first-of-kind technology to assess fragmentation presented to the shovel at the digging face. A Digital Vision System (DVS) was installed on one of the shovels to capture images that were stamped with GPS locations. A large population of digital images were analysed to produce a robust fragmentation distribution baseline that was used as one of the mine key performance indicators (KPI). Changes to blasting practice were subsequently measured against the baseline KPI to assess effectiveness.

Jan 1, 2011

By Greg Bold, Mahmood Khwaja, Yuannian (Jerry) Wan, Michael S. Schultz, William Simcoe

Beaver Creek Clean River Project will satisfy the consent decree requirements by capturing and treating combined sewage overflows. The project consists of, approximately, 2,700 feet of 30-inch trenchless pipe installation, a new screening/disinfecting facility, an expansion of an existing diversion structure, and a 72-inch internal diameter, 530-foot long mined tunnel. The tunnel portions are being progressed as early release packages. This paper presents the geotechnical exploration program and the subsurface conditions encountered; interpretation of the geotechnical conditions; and, approach to developing stand-alone packages for the tunnels to mitigate construction and schedule risks and continue to advance the project.

Jun 13, 2021

By R. L. Eppley

The Blacklick Creek Watershed Association was awarded a $158,000 Growing Greener grant from the Pennsylvania Department of Environmental Protection in 2002 for the design and construction of a sulfate reducing bioreactor (SRBR) cell to treat acidic discharge from the Judy 14 abandoned underground coal mine near Indiana, PA. The vertical flow SRBR was designed to treat 38 liters per minute of MIW containing elevated concentrations of aluminum and iron. Other treatment systems at this site plugged due to aluminum precipitates; this problem did not occur in the SRBR. The bioreactor has been periodically overloaded with flows up to six times the design rate. To date, the only maintenance performed on the unit has been the addition of hay to the surface of the unit in response to less than expected performance. The periodic hay additions appear to have restored the SRBR to nearly post-construction levels. Since construction, the SRBR has treated about 136,000 cubic meters (36 million US gallons) of MIW.

Jan 1, 2010

By Yuting Xue, Gamal Rashed, Zoheir Khademian, Morgan Sears

Mining has been recognized among the most hazardous industries in the United States, despite the significant reduction in injury and fatality rates over the past century. This study focuses on the ground-fall incidents classified in the Mine Safety and Health Administration (MSHA) database as “fall of roof, back, or brow from in-place” and “fall of face, rib, pillar, side, or highwall.” The main objective of this study is to conduct a comprehensive statistical analysis of the reported ground-fall incidents from 2010 through 2019 including both coal and metal/non-metal mines. Since most of the ground-fall injuries and fatalities occurred in underground coal mines and were attributed to falls of roof and rib, an additional analysis was directed to evaluate roof- and rib-fall incident trends in underground coal mines associated with the mining method, coal-seam thickness, mine size, and the seasonal effects.

By M. B. Haggerty, R. J. Sheets, F. Abbasy

To address coal refuse tailings storage needs for a mine operation in western Canada, a feasible solution was to convert excavated open pits into tailings cells. A slope stability investigation and design study were completed to determine the necessary width and slope geometry for in-situ native plugs as the impoundment embankment. The native plugs separate the previous open pit from the current active open pit. This configuration allows for the deposition of refuse tailings in the previous pit while allowing mining to safely continue “downstream” of the temporary impoundment. As mining progresses, each subsequent pit will be filled with refuse tailings; thereby, buttressing the upstream slope of the previous native plug. Although these cells are excavated, and the timeframe for downstream exposure is relatively limited, the native plugs are classified as dams and must be designed to meet applicable safety of dam standards since they impound water and tails above mining personnel in the subsequent open pit. The presentation and paper will discuss the investigation and analysis conducted to develop the geotechnical and hydrogeological design recommendations.

Mar 2, 2022

By C. Williard

Computer based mine monitoring and control systems represent a relatively new technology to be applied in the U.S. mining industry. While computer assisted engineering, design, and planning have been accepted as tools for specific technical and engineering jobs within the industry, integrating mine-wide monitoring and control systems into mining operations has been slow. This paper reviews the state of the art of mine monitoring and control systems and provides insights into future trends and developments.

Jan 1, 1988

By T. Shumka, M. J. Druckenmiller

"INTRODUCTION As we push further into the 21st century and closer to a more efficient mine, safety and operational enhancements are the two major keys towards attaining success. The Crusher Vision Automation System (CVAS) is a technological advance that will allow an operator to achieve higher safety and higher operational goals in the same piece of equipment. The CVAS is a patent pending system and method for measuring and maintaining the closed side setting (CSS) on gyratory crushers. In the same equipment and technology package, the CVAS will also allow safer placement of main shaft pieces for maintenance and replacement. This technology yields multiple uses and allows a site to significantly enhance safety and operational efficiencies. This measurement technique is used to provide more accurate data and faster data collection times than current techniques used today. It will give crusher operators accurate and reliable measurement for the CSS in a live, operating environment. Measurement data can be collected in five minutes allowing for fast adjustment of the mantle position and subsequent enhancement and streamlining of a crusher and downstream flowsheet. The advantage of this system is that it is permanently mounted at the crusher location, where the operator can turn the system on and off as many times as they like throughout the day with a goal of maintaining a constant CSS gap based on production and maintenance criteria to help streamline operations and enhance safety efficiencies.Regarding its other main functional area, mainshaft maintenance, it allows this work to be performed remotely while keeping personnel safer and out of harm’s way. SAFETY ENHANCEMENT The safety factor enhancement with this system is extreme. It does not require the use of overhead cranes, cleaning out the crusher, lowering people into the crusher or having the operator lower paint cans or lead balls into the crusher pocket while the crusher is in operation for measuring the setting. In order to perform the CSS measurements, the operator only needs to operate the laser through manipulation of a joystick while watching the video feed. Danger of a person falling into the crusher while trying to take measures is eliminated, as are the effects of handling lead balls and tracer dyes."

Jan 1, 2015

By J. Pancher

"Stainless steel castings are used in abundance in the mineral processing industry. In rotary kiln-based processes, these castings are typically exposed to high loads, corrosive elements, mechanical abrasion and cyclical temperature exposure. In the processing of iron ore pellets, it is typical to use a traveling grate preheater or a straight grate furnace to heat the pellets. Both machines have a conveyor that is mainly comprised of high temperature stainless steel castings. It is these castings which are the focus of this study. The expected life of these castings can be quite short, their cost quite high and the effort to replace them very labor intensive. The goal of this study was to gain a better understanding of the failure modes of these castings. With that basic understanding, modifications to the alloy content could be made to achieve a new operational paradigm. That paradigm could be a cheaper casting, a longer lasting casting or a casting tailored to special operating conditions (for example, highly corrosive gases or sudden temperature shocks). Over the past 4 years, Metso Minerals has sought to achieve a better understanding of the failure modes through modeling, laboratory testing and sampling of used castings from various end-users. In addition, we have tested new alloys in a laboratory setting and also in the field to see how they would perform compared to the existing ""standard casting"". Our testing has revealed interesting data concerning the impact toughness, sigma phase content and formation, chloride attack and other performance attributes of various grades of stainless steel when exposed to cyclical temperatures. Interesting results were also obtained concerning the addition of rare earth elements (Niobium, Boron, etc), nitrogen and manganese to a typical ASTM A297 grade of stainless steel. To date, a few hundred test castings have been installed in iron ore pellet plants worldwide. Many of these test castings have already experienced a year or more of operation with good results.INTRODUCTION Cast stainless steels (ASTM A297 and similar) are a main constituent used in the construction of iron ore pelletizing equipment. A typical straight grate pelletizing machine would contain upwards of 160,000lbs of ASTM A297 Grade HH castings. With a typical casting lasting only two to four years, and a casting costing around $35USD, it is easy to see that the castings are a main contributor to the overall cost of producing the pellets. Grade HH and HI (see chemical composition listed below) became the “go to” materials in the 1960’s and very few changes have been made to this day (the exception being plants that switched to flux pellet production in the 1980’s)."

Jan 1, 2015

By D. Royston

A novel low-cost technology is described that treats excavation waters in estuarine environments where water coloration due to humic material is present, along with acidity, turbidity, sediment and salinity. The process treats all the components in the water to produce a clear (color-free) water stream that meets requirements for direct discharge to local estuarine waterways.

Jan 1, 2003

By Christopher J. Hall

This paper describes the results from computer runs simulating 24 different mine ventilation configurations with the main fan situated first at the top of the upcast shaft and then at the top of the downcast shaft. Real air was used, with evaporation, condensation and heat exchange. The results showed that power requirements for the forcing fan were up to 20% less than for the exhausting fan for equal mass flow rates.

Jan 1, 1989

By K. N. Hebbar, R. G. Reddy

Spent potliners (SPL) were declared hazardous waste under RCRA (K088) in July, 1990. The glass formation characteristics of the SPL was studied. The SPL glassy matrix were analyzed using X-ray diffraction and optical microscopy. Results showed that SPL can be fixed in a glassy matrix with the addition of sand and limestone. The optimum amounts of additives were determined for obtaining the best glass formation characteristics.

Jan 1, 1995

By A. R. Zambrano

Equations for Power Draw, Capacity, and Work Input for predicting the performance of industrial grinding mills are derived based on torque measurements obtained in a laboratory instrumented mill. These derivations are based on mechanical principles and on the first order kinetics of the grinding process. Rittinger's, Kick's and Bond's laws express Work Input as Work Index, W;, times a Particle Size Function. These laws are only particular cases of more general expressions having the Particle Size Function raised to an exponent, the Work Exponent We. Case studies illustrate the excellent prediction of the W;-We models, compared to the three mentioned laws.

Jan 1, 2001

By C. Patrick, T. Combs

The purpose of this paper is to provide a method for analyzing the sequencing of mining production processes and predicting the effects of any planned changes. Included is a description of the development and utilization of a project-scheduling simulation that combines analytical scheduling with stochastic-activity durations. The simulation is demonstrated in two realistic examples: a longwall face-to-face transfer sequence and the effect of varying advance rates on longwall development sections. Statistical data that can provide a basis for more informed production decisions are generated in the form of project activity/path criticality and project-duration distributions. In both examples, a quantitative risk assessment, regarding subjective decisions in underground production sequencing, is presented.

Jan 1, 1996

By P. G. Semple, K. W. Major, R. M. Nendick

As free milling oxide gold ore reserves are depleted, more mining companies are having to evaluate the available alternatives for treating refractory deposits. The selection of a treatment process can be very difficult; and, despite the claims of their respective proponents, there is no one process that will continuously prove superior. Selection of the optimum process for an individual deposit is contingent on the size of the deposit, the grade of the deposit and the refractory nature of the ore. Since extensive metallurgical test programs are usually required to determine the optimum extraction process, an inappropriate initial selection may prove costly and time consuming. This paper discusses the steps involved in evaluating a refractory ore in order to expedite the evaluation of the required process through the feasibility study stage.

Jan 1, 1990

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

In many mining operations, particularly northern open-pit mines, large seasonal variations in grinding slurry temperature can occur. It is shown in this paper that this temperature shift can cause a winter-time loss in autogenous grinding efficiency of as much as 20% if it is not controlled. Laboratory experimentation indicates that much of this effect is due to increases in slurry viscosity as the temperature is decreased. An additional effect may result from changes in rock strength upon freezing, for which possible mechanisms are discussed. However, no effect clearly resulting from rock strength changes has been definitely confirmed.

Jan 1, 1992

By S. K. Kawatra, T. C. Eisle

In froth flotation of phosphate, it is important that the flotation be as selective as possible in order to maximize grade and recovery without adding additional stages of flotation. Flotation columns provide a means for improving the selectivity compared to conventional flotation machines and are of considerable interest for phosphate processing. The selectivity of a flotation column is largely limited by the degree of back mixing of tailings into the froth zone, and its recovery is limited by the degree of short-circuiting of feed to the tailings. The horizontally baffled flotation column was therefore developed to minimize back mixing and short-circuiting without introducing problems with plugging or reduced capacity. The introduction of horizontal baffles to a column reduces both entrainment of feed water into the froth and short-circuiting of feed to the tailings, which improves the column selectivity. The results of horizontally baffled column flotation of phosphate are presented for fatty acid flotation of phosphate, with comparison to conventional flotation using the same reagents.

Jan 1, 1999

By Cheng Ang, Yun Bai, Zhi Liu

"This paper presents a conceptual design of an innovative tunnelling method named the Ring Pipe Jacking Method (RPJ) which is conducted by the Ring Pipe Jacking Machine (RPJM). The RPJM consists of a double ring shell which forms a ring section where small interlaced cutter heads or several micro tunnelling machines are assembled to cut soil. Similar to the conventional pipe jacking method, the RPJM also needs a thrust system, a slurry transport system, and a control system. To satisfy the need for large/super large or special section tunnels in future, the RPJM is designed to reduce sharply the excavation face to the annular section, thus enhancing the face stability. Part of the innovation is that the RPJM uses modular cutter heads or micro-TBMs which can be reused. The typical double shield shape can be easily changed by reinstalling the modular cutter heads. Modularity allows the tunnel to be cut in any cross-section shapes, ranging from a circular tunnel to a rectangular one. INTRODUCTION The demand and requirement to utilize urban underground space is rising with the rapid social development in recent years. It is necessary to reduce excavations of the urban ground surface to ensure smooth traffic in cities. Therefore the conventional open cut construction method for underground tunnels can no longer satisfy the need of practical engineering, and it is taken over by trenchless technologies .The Pipe jacking method is an important trenchless technology and is used more and more frequently to install underground pipelines, but the present pipe jacking method still has many problems. For example, it is not suitable for installing large-diameter tunnels and it also has difficulty in construction of short radius curved tunnels. This paper presents a conceptual design of an innovative pipe jacking machine named the Ring Pipe Jacking machine (RPJM) and introduces the correspondent Ring Pipe Jacking Method (RPJ) which can be applied to construct large-diameter tunnels. Furthermore, technical characteristics and superiority of the ring pipe jacking method are analyzed in this paper."

Jan 1, 2016

By Priscilla P. Nelson, Francis L. C. Fong

Introduction Fracture mechanics is the study of the behavior of cracks and their modes of propagation. During cracking, energy is consumed in creating new surface area. The more energy a material absorbs, the higher is its fracture resistance. This fracture energy is provided either by work done externally, by the release of elastic strain energy within the cracked body, or by a combination of these two effects. Fracture resistance is measured in terms of either the stress intensity factor, K, or the energy release rate (also referred to as crack driving force), G. For linearly elastic materials, these two quantities are related by the following equation: [ ] where [u] is Poisson's ratio and E is the modulus of elasticity. Both K and G are direct functions of the applied force and the crack length. The process of rock cutting with full-face tunnel boring machines (TBMs) involves the indentation of a rock surface by rolling disc tools. Excavation occurs as fractures, extending from the locus of chip indentation, propagate between concentric disc grooves and liberate rock chips from the intact rock face. Since disc cutting is achieved by a fracture process, it is logical to anticipate that differences in cuttability of a variety of rocks should be related to the variation of fracture material properties among the rocks. Such a relation has been demonstrated between the performance of full-face TBMs and the critical crack driving force for excavation in relatively high strength, brittle, low porosity, isotropic rock (Nelson et al., 1985). The objective of this paper is to report on the results of a continued investigation of the relationship between fracture material properties and the effectiveness of disc cutting. Additional reliable data on full-face TBM performance is difficult to obtain, so that the results of disc linear cutter tests performed by the Transport and Road Research Laboratory (TRRL) (U.K.) are utilized in this study. Fracture Material Property Evaluation If a crack tip is subjected to a perfectly plain strain condition, many materials will behave in a brittle manner, and the material resistance to fracture is constant during crack growth. This resistance is referred to as the plain strain fracture toughness, believed to be a material property. The standard testing procedure for this parameter is given in the American Society for Testing and Materials (ASTM) test designation E399. To ensure plain strain conditions, acceptable specimen geometries are specified. Unless these geometric specifications are adhered to, the measured fracture resistance is regarded as the apparent fracture toughness, and a subscript Q is used, as [ ]. The methodology adopted by ASTM E399 is within the framework of Linear Elastic Fracture Mechanics (LEFM). This approach assumes that material resistance against cracking is developed instantaneously, without initial stable or subcritical crack extension. Prior to crack advancement in rock, however, much of the crack driving energy is absorbed in a localized volume in front of the crack tip, referred to as the plasticity or microcracking zone. This capability for energy absorption substantially increases material resistance, and a crack may be arrested unless an increased crack driving force is applied. The LEFM or plain strain assumptions would underestimate the actual fracture resistance of such a material. Such a conservative approximation may be desirable in the design of structures against fatigue or brittle failure. In mining or tunneling, however, an underestimation of crack resistance can lead to the selection of underrated excavation equipment and a decrease in production efficiency. The development of fracture resistance in rock is best described by the material resistance curve, or R-curve, which is a plot of fracture resistance as a function of crack extension. Typically, peak resistance is only reached after a finite amount of subcritical crack growth. The

Jan 1, 1986

By Jacob Carr, Christopher C. Jobes, Chenming Zhou, LaTasha R. Swanson, Jennica Bellanca, Jingcheng Li

Magnetic proximity detection systems (PDSs) are used with continuous mining machines (CMMs) to protect miners from striking and pinning accidents. Generators are used in a PDS to create magnetic fields covering the space around a CMM. The PDS determines the proximity of a miner relative to the CMM based on the magnetic flux density detected by a miner-wearable component (MWC) and simultaneously alerts the miner and stops the motion of the CMM if the miner is within a proximity that creates a striking hazard. A stable magnetic field is essential to the accuracy of the proximity calculations performed by the PDS. This paper presents the results of a systematic study of the magnetic influence of two types of steel structures found near a CMM— the body of the CMM itself and the wire mesh used for roof and rib control. The results show that the steel of the CMM body can change the magnetic field distribution and also alter electrical parameters of a PDS by changing its generator current. The study also shows that, depending on the distance between the wire mesh and a generator, the magnetic field can also be altered.