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By J. Duarte Neto, V. M. Torres, A. Viana, G. S. P. Pereira, P. M. Andrade

There are technical and commercial limitations to using high fluorine copper concentrates in industrial copper smelters. The presence of more than 1,000-ppm fluorine affects the sulfuric acid units generally integrated to copper smelters. Price penalties are normally applied to copper concentrates with high fluorine contents. Several process alternatives to resolve this issue were studied at the Companhia Vale do Rio Doce (CVRD) Technology Center, Santa Luzia, Brazil. These alternatives included modifications to conventional sulfuric acid plants so that they can use high fluorine concentrates; removal of fluorine-containing minerals by flotation using depressants; selective leaching of fluorine minerals; and sulfuric acid leaching of the copper concentrates. As a result of this research, a hydro¬metallurgical process to remove fluorine and upgrade copper concentrates was developed by the CVRD.

Jan 1, 1999

By G. F. Revey

All underground operations have limiting factors that influence overall profitability. Hoisting, hauling, available headings, labor, milling capacity and other factors limit how much material can be removed from an underground mine. Consequently, when mines use limited labor to handle the additional rock from overbreak and to perform extra ground support tasks, productive activity is replaced by nonproductive work. Mining economics are further penalized when overbreak causes dilution of ore grades. This paper reviews the organizational systems that mines have been using to create environments that foster the creation of successful overbreak-control programs. Actual case histories document the various quality-improvement techniques, worker incentives and practical project-management systems used by these mines. A brief review of controlled-blasting technology sources and overbreak-measurement tools is also included.

Jan 1, 1999

By Lit-Mian Chan, David H. Carlson, John H. Johnson

This paper presents an apparatus and procedures to implement a methodology for controlling ambient air quality in a confined working environment, such as an underground mine, an underground storage area, or a tunnel. The air quality control methodology is directed at limiting the quantities of exhaust pollutants emitted by diesel-powered vehicles into the confined space by identifying vehicles that are excessive polluters. The methodology is based on tailpipe and ambient air measurements in the confined space, and the ambient air threshold limit values (TLVs) for the various diesel exhaust pollutants. The methodology consists of two computational methods; a deterioration criteria computational method to identify excessive polluting vehicles, and an engine performance computational method to determine engine performance and to provide information needed to diagnose engine faults. The methodology is designed for implementation in conjunction with a preventive maintenance program. The first part of the paper describes the mine air and tailpipe emissions measurement apparatus and techniques used to obtain data. This is followed by sections discussing the deterioration criteria and the engine performance computational methods. A section discussing some common engine emissions-related faults is also presented. Lastly, a proposed procedure to implement the methodology including a possible hierarchical structure for mine personnel involved to implement the procedures is presented.

Jan 1, 1993

By R. W. Barbaro, R. V. Ramani

Generally, production planning is concerned with the best use of fixed resources to determine a production schedule for one or more production units supplying one or more markets. Production scheduling determines when each production unit will be used and its production level. However, the production scheduling problems are intimately associated with the location of existing or new production units and processing facilities. Normally, mine location allows only a limited choice; processing plant types and locations are considerably more flexible. This paper presents a generalized multiperiod MIP model as an aid in determining the mine production schedule and the processing plant types and location to satisfy multiple markets. A brief description of MIP and how it has been applied in the mineral and other industries is discussed. A complete description of the model with an application to a coal preparation plant system is presented.

Jan 1, 1987

By R. Fraher

The control of mine roof is of vital interest in underground coal mining not only for reasons of safety, but also to avoid the high costs of cleanup, resupport and production losses that can result from roof falls. The difficulty in determining roof stability mine-wide is due in large part to the broad variation of geologic and structural conditions that typically exist throughout a mining area. To ensure a stable roof over the entire mine, support systems must be selected to minimize the possibility of failure. The magnitude and cost of the support selected is a trade off against the cost of the number of falls that can still occur after it is installed. Because of the large number of variables involved in analyzing and optimizing roof stability versus support, a digital computer simulation was selected to find a cost effective solution to roof support design. A total cost approach is used which includes the actual cost of the roof support as well as the cost of the roof fall in terms of resupport and loss of production (Fraher 1990a). A Monte Carlo simulation program called ROCSIM (Roof control Optimization Cost SIMulation) has been developed for determining the optimum roof control system and design layout for underground room-and-pillar mining.

Jan 1, 1992

By B. J. Arnold

Coal froth flotation cells typically receive little attention in coal preparation plants. They process only a small portion of the total coal feed (perhaps 5-1 0% of the total plant feed in the United States), they are viewed as a way to take the load off the refuse thickener, and their operation is not well-understood by cleaning plant operators. Operating parameters are set based on the equipment supplier information, and reagent dosages are set at the recommendation of the latest chemical vendor. The cells then operate day in and day out, recovering coal and producing a product that may not meet ash or sulfur specifications or that may be the wrong percent solids for downstream dewatering operations. If improvements can be made to this circuit, then the whole plant will benefit. Paying attention to rate and residence time and the wealth of data from the literature or from a series of targeted laboratory tests can give operators the key to improving the performance of froth flotation cells AND overall plant performance. This paper provides an overview of froth flotation rate and residence time data and gives practical suggestions for specifying and using laboratory tests to improve froth flotation performance. Suggestions for improving froth cell performance are also given based on available literature data.

Jan 1, 1999

By John Nadolski

Intensive hydrologic monitoring of the Powder river basin has been on-going since the early 1970's. Data were used in environ- mental assessments and for determination of hydrologic consequences associated with coal mining activities. For most coal mine operators, data collection has continued in this baseline mode with little or no statistical analysis of the data and with no statistical procedure established to detect changes in groundwater quality. For the past four years Powder River Coal Company has studied several statistical techniques to analyze groundwater quality. Three objectives were pursued: 1) to determine the baseline water quality for key aquifers; 2) to determine which wells could be deleted from the monitoring program without reducing monitoring effectiveness; and 3) to define a statistical test to determine water quality changes. Knowledge of the regional geo-hydrologic system was combined with an analysis of the water quality monitoring in order to identify homogeneous aquifer zones. All wells within an aquifer zone were treated as one population, and a t-test was used to determine the minimum number of samples needed to define the water quality for each aquifer zone. Results indicate that the data for each aquifer zone were nor- mally distributed and that groundwater quality could be defined using a fairly small number of samples. Because of the minimum sample size test, groundwater quality sampling was reduced by between 75 and 85 percent.

Jan 1, 1989

By Terry L. Logan, Arfon H. Jones, James C. Seccombe

Deeply buried coal seams [greater than 3000 ft (914 m)] are difficult and sometimes hazardous to test and complete due to coal sloughing, formation pressure anomalies and coal fine generation. Data collected while stimulating two deep coalbed methane wells located at the Gas Research Institute/Resource Enter¬prises, Inc. "Deep Coal Sean Project" test site in the Piceance Basin, Colorado, is presented in this paper. A single thick coal seam was completed openhole in each well. Core data, reservoir data, in-situ stress measurements, and pre-stimulation calibration test data were collected at the site to use in the design of the fracture stimulation treatments for both wells. A nitrogen foam fracture fluid treatment was selected for the first well and a linear gelled water for the second well. Treatment pressures were monitored with a downhole quartz pressure transducer. Atypically high treating pressures were observed, possibly indicating coal fines plugging at the fracture tip or increase in fluid viscosity caused by interaction of the generated coal fines with the fracturefl uid. In addition, a comprehensive fracture diagnostic effort was employed during the fracturing of the second well; namely, triaxial borehole seismic, seismic televiewer, hydraulic impedance monitoring, gamma ray log (in conjunction with radioactive additives in the sand), and temperature log. The results indicate a vertical fracture was created parallel to the face cleat as expected.

Jan 1, 1986

By John D. Gardner

This paper describes a process which finds the maximum worth of a mineral deposit. The procedure requires two phases. The first uses a microcomputer evaluation model to find the optimum design input, with minimum attention giving to actual mining constraints that might exist. The second phase runs the first-phase design parameters through a direct simulation model on a mainframe computer. In phase one, financial, economic, and geotechnical data are entered; and an idealized list of design parameters is output. The list includes optimum values for cutoff grade, mine life, mine size, paytons, paygrade, and payvalue. In addition, the model generates pro forma operating and cash flow statements and it indicates the maximum net present value (NPV) possible for the deposit along with the probability of that oc¬curring. The initial results imply perfect mining conditions. In phase two, when actual mining selectivity, sequence, and other practical design considerations are related in a direct simulation model to the optimum criteria found above, the maximum NPV invariably decreases. However, if it is still satisfactory (NPV greater than or equal to zero) then the maximum worth/ optimum design have probably been found in the first iteration. If, on the other hand, NPV is now unsatisfactory, then design compromises must be made and simulated, and the results rerun through the evaluation model. If several iterations fail to yield a positive NPV then the deposit is most likely unfeasible t for the forecast economic conditions used in phase one.

Jan 1, 1986

By M. S. Basich, J. S. Scope1, J. H. Raeder

During 1983, The Youghiogheny and Ohio Coal Company's lost-time-incidence rate was 8.1, equal to the average for underground bituminous operators. How- ever, one half of all lost-time injuries were low back, back and neck related. In reviewing these results, we determined that substantial improvement could be made. We investigated existing back schools and the possibility of opening an in-house clinic. In September 1984, we began The Youghiogheny and Ohio Coal Company's Back Care Program. The objectives of the program are to reduce the number of back injuries incurred at the work site, hasten recovery time, decrease medical and workers' compensation costs and provide the employee with a thorough understanding of his problem. A state-of-the-art clinic capable of treating injuries to the spine and extremities has been established at the work site. The clinic is staffed by a licensed physical therapist and is offered to all employees on a voluntary basis under physician referral. The approach to treatment is multi-phasic. For the typical patient, the initial goal is to reduce pain and correct dysfunction. Treatment modalities such as auto-traction, extension exercises, ultra sound and moist heat are frequently used. During this period the patient is given extensive education regarding his problem. As soon as more vigorous activity can be tolerated, a work-hardening pro- gram consisting of job simulation activities designed to improve flexibility, strength and functional capability is begun.

Jan 1, 1986

By P. D. Pack, E. H. Skinner

During design of a 550-foot rectangular shaft in alluvium, lateral support within the excavation was an anticipated construction problem. Actual experience showed that the nearly 9 x 14 foot excavation required no lateral support. A strain measurement program con- current with construction and for a 9-month period following completion of the shaft detected only minor strains. Shaft design included consideration of available geological information. Site exploration included a 754-foot drill hole, cored at selected intervals, and a suite of geophysical well logs. Generalized physical properties of the alluvium were developed from laboratory core testing. An elasto-plastic, finite element computer program (DAHLKE) developed by the Spokane Mining Research Center U.S. Bureau of Mines, has been recently used to analyze the behavior of the alluvium around the shaft. Analysis showed that yielding first develops in the shaft corners and progressively expands into the wall zones around the shaft as loading increases. Gradual growth of a plastic zone progressed outward from the excavation boundary at increasing loads but had limited extent and was surrounded at all stress levels by an infinite elastic zone. This design review, aided by computer analysis, confirmed that the shaft would have been considered theoretically stable as designed.

Jan 1, 1977

By M. K. Gangal, E. D. Dainty

The paper describes the use of portable aerosol monitors in determining real-time concentrations of diesel soot and respirable total dust in dieselized mines. The field studies were conducted in a simulated diesel environment in the laboratory where no other type of dust was present, and in four underground mines with multi-diesel machine operations. Two packages for the real-time monitoring of diesel soot were prepared which included two types of aerosol monitors: a Miniram, model PDM-3, and a Sibata, model PDS-1. These monitors utilize the principle of light-scattering to measure the airborne mass concentration in the environment. The monitoring device results were compared against the Time-Weighted-Average (TWA) values produced by the gravimetric filter sampling method, permitting calibration factors to be determined for each field test. Both instrument packages provided comparable results. The instrument calibration factors varied for different tests, which may be due to different material composition, particle size distribution, density and shape of the aerosols. This approach for real-time determination of diesel soot is found to be simple, inexpensive and easy to use. More field tests for diesel soot determination and further research on size distribution of particulates in dieselized mines are required.

Jan 1, 1989

By T. X. Ren, J. S. Edwards

Although much work has been carried out in order to understand the mechanism of spontaneous combustion and hence minimise its potential risk, the spontaneous combustion of coal continues to be a problem in coal mining. The Department of Mineral Resources Engineering of Nottingham University has been active in conducting fundamental research into the problem of spontaneous combustion of coal. For years standardised adiabatic oxidation tests have been used to identify coals and other carbonaceous materials liable to spontaneous combustion. Recently the apparatus has been computerised and coupled with an expert system known as ESSH to evaluate the potential of self-heating of coal on the basis of intrinsic coal properties, geological settings and mining techniques. A numerical model has been developed to study the aerodynamics of airflow in the wastes of longwall coal faces. The Computational Fluid Dynamics approach is being explored to simulate airflow behaviour and nitrogen inertisation processes within the goaf. Such a model would be used in locating the areas most liable to spontaneous combustion and improving the utilisation of nitrogen. It would also be possible to determine the most likely path ways of combustion/heating products so as to provide an indication of the most appropriate locations for fire detectors.

Jan 1, 1997

By R. Worrall

The global mining industry has been proactive over the last decade in finding ways to embrace the concept of sustainability. However, legacy mine sites (which include abandoned derelict and orphan mine sites) across the world continue to present issues for the global mining community, governments, local communities and NGOs. Unfortunately there has been much less academic focus on this area of mining and sustainability. This paper seeks to address how principles of sustainable development can be used to guide the development of processes for addressing post mining landuse issues for legacy mining areas. This is being done using a case study area located near Ipswich, in southeast Queensland, Australia. This area has a 160 year history of coal mining, and was one of Queensland?s crucial early industries. Mining in the area ceased in 2003 leaving a degraded landscape covering an area in excess of two thousand hectares adjacent to one of the fastest growing urban areas in Australia. A sustainability criteria and indicators framework for post-mining landuse on legacy mined land, developed from current best practice used for measuring sustainability across a range of industries is being developed. A review of current best practice suggests the framework should: (1) consider in equal measure environmental, social and economic factors; (2) have a minimum number of indicators which should be easy to identify and measure; (3) must have indicators with a meaningful output; and overall, the framework must consider particular requirements of the site being investigated. Application of the framework to the case study area is an ongoing aspect of this research, and the results will be evaluated through the use of expert stakeholders.

Jan 1, 2007

By K. S. E. Forssberg, S. Subramanian, Hanumantha K. Rao

The dispersion characteristics of apatite and magnetite minerals have been assessed based on zeta-potential measurements, using various inorganic and organic reagents, namely sodium silicate, sodium tripolyphosphate, sodium hexametaphosphate and lignin sulphonate. These results highlight that apatite is dispersed to a greater extent vis-à-vis magnetite. Further, the dispersion efficiency of the phosphate reagents is better than that of sodium silicate or lignin sulphonate, for both apatite and magnetite. Batch flotation tests on a high phosphate magnetite ore from Kiruna indicate that higher apatite recovery with minimum phosphorous loss to the magnetite fraction can be achieved using sodium silicate as a dispersant. Although comparable dephosphorization can be attained with lignin sulphonate dispersant, the recovery of magnetite in the non-float fraction is lower, possibly due to the adverse synergistic effect of this organic reagent with the Atrac collector, resulting in the flotation of magnetite. The high intensity conditioning of pulp for up to 30 min resulted in better apatite flotation with <0.015% phosphorous in the magnetite product.

Jan 1, 2002

By F. D. Mendes, A. H. Martins

The high copper grade in the Igarapé Bahia (Brazil) gold-copper ore restricts the direct application of the classical cyanidation process. Copper oxide and sulfide minerals react with cyanides in solution, causing high leach-reagent consumption, raising processing costs and decreasing gold recovery. According to studies, a feasible solution would be to pretreat the ore to remove copper minerals prior to cyanidation. The goal of this experimental work was to study the conditions for the removal of copper from the Igarapé Bahia gold-copper ore by sulfuric acid leaching, applying a statistical approach to the experimental design. By using the Plackett Burman method, it was possible to select the variables that exhibited the largest influence on copper extraction at the sulfuric acid leaching stage. These variables were leach solution temperature, stirring speed, sulfuric acid concentration in the leach solution and ore particle size. The individual effect of these variables and their interaction influences on the experimental response were analyzed by applying the replicated full-factorial design method. Finally, the selected variables were optimized by the ascending-path statistical method, which determined the best leach experimental conditions for maximum copper extraction. The optimized leaching conditions resulted in a copper extraction of 75.5%. Keywords: Copper, Gold, Extraction, Sulfuric leaching, Optimization

Jan 1, 2003

By N. R. Joshi, A. D. Agate

It is estimated that more than 80% of phosphate rock output in the world is used for fertilizer production. In India, there are only a few high-grade deposits of phosphate ores; therefore, most of the requirement for phosphatic fertilizers is satisfied with imported DAP (diamino phosphoric acid). Due to the drain on foreign exchange reserves, this import-dependent, essential commodity is in short supply in India and, therefore, is sparingly used by farmers. In addition, of the added phosphorus, normally 80% becomes unavailable to plants because phosphorus complexes are formed in soil, causing deleterious effects on plants. In our laboratory, this problem was tackled by using a bacterial consortium of phosphorus-solubilizing bacteria. It resulted in the speeding up of seed germination and increasing available phosphorus in the soil by 14%, over a period of 80 days. To use the low-grade deposits of phosphatic rocks available in India near Hirapur, Madhya Pradesh, India, which contain high amounts of iron, beneficiation through microbial means was used for phosphorus removal. Beneficiation was achieved partially through removal of extra iron by oxidizing ferrous iron from the ore by a Thiobacillus species after removal of impurities containing both silica and iron, instead of sieving and cleaning the ore using different techniques. This resulted in a cleaner ore, with nearly 70% of such impurities removed. The factors for beneficiation technique were standardized at the laboratory level and are being used for scaling up of the process. Thus, the beneficiation of phosphatic rock from Hirapur will be an important first step of phosphorus production in India.

Jan 1, 1999

By S. S. Peng, Luo. Y.

In a shearer longwall mining operation, the longwall hits are responsible for breaking into and chipping the broken coal blocks away from the coal face. However, underground observations found that the bits being used were working under various degrees of wear. This wear can be reduced by using better-designed longwall bits and by properly selecting shearer operating parameters. A computer program was developed to simulate the performance of the longwall bits. The information required by the program are the shape of the bit head, the installation of the bits on the drum and the operation parameters. Through the simulations, the main factors affecting the bit-wearing process are identified. Suggestions are also made for improving the design of the longwall bits.

Jan 1, 1998

By Jorge Gutierrez C.

CODELCO-CHILE, the world&apos;s largest copper producer, began an integrated study of the informatics situation in the corporation at the end of 1980. As a result, a five years strategic Systems Plan was elaborated and approved by top Corporate management. Main points in this plan were: a systems architecture with information integration to the top level management; a higher degree of information technology in the production areas, an optional systems development resources utilization and a high profitability of the plan itself. During the study phase a series of theoretical definitions were fixed and used as a basis for the plan&apos;s design. A "common systems" approach was chosen as the development strategy instead of corporate systems or separate divisional efforts. Top management should be highly involved in the revisions of the plan, as well as qualified users should be chosen as project managers. The systems architecture should grant the information integration to the corporate level, in order to support an integrated planning and administration environment for the corporation. A total of 15 projects were defined, involving 570,000 man-hours and shifting the development efforts towards the production and production services areas. The paper presents a critical evaluation of the whole process, showing its good and bad aspects and a positive global balance. It also points some suggestions and hints to any corporation who wishes to get involved in a similar experience.

Jan 1, 1989

By B. Rao Pothini, Julio H. Thaler, W. L. Finlay

The White Pine room-and-pillar mine started in 1955 from a suboutcrop, down gentle dips, and with a competent sandstone roof. As mining depths increased, extraction decreased 1% every 35 feet. Moreover, roofs became shaly and less competent, and regions of high fault and joint densities, sometimes with and some- times without high lateral stresses, increased the tendencies towards roof falls. Instinctive reactions towards narrower openings did not alleviate the problem. Careful consideration of rock mechanics principles culminated in the development of two variants to the conventional room-and-pillar mining system based on the concept of stress relief through load deflection. The two systems-EquiAdvance Cave, and PressureArch Panel Mining-are complementary. The objective of the former system is to provide relief from lateral stresses through advance caving and in the process also to achieve higher extraction at depth. Where surface subsidence cannot be allowed, the alternative PressureArch Panel concept is utilized to provide stress relief and moderately high extraction ratio. Both systems have been under trial for over three years and, together, produced over three million tons of copper ore. These two systems, and their production test results to date, are described.

Jan 1, 1977