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By Rambabu Pothina, MELO EDUARDO PIMENTA DE, Rajive Ganguli

 The mining industry is home to a mass of sensor-generated data that are critical to real-time and long-term optimization. This heavy reliance on sensor data has resulted in an undesirable development. The industry is reluctant to verify the accuracy of sensors as it would mean shutting down important processes. Sensors are typically calibrated once a year, if at all. Errors in sensors go undetected until the next calibration or until errors are so gross as to be obvious

By B. H. Kim, P. Zhang, M. A. Van Dyke, D. Su, H. Dougherty

The National Institute for Occupational Safety and Health (NIOSH) has been evaluating longwall mining-induced strata fractures and their impacts on casing stability of Marcellus shale gas wells located in longwall pillars. To understand the extent of overburden fractures after longwall mining, NIOSH researchers drilled a postmining corehole into the fractured strata above the Pittsburgh coal seam longwall gob. Knowing the extent of the fracture zone height will help gas operators minimize the hazards of drilling into longwall gobs. The core was retrieved from the surface down to the top of the gob void. Various fractures were encountered varying from 35 to 64 degrees, depending on lithologic type and relative closeness to the gob. The longwall panel dimension was 457 m wide and 3657 m long, in which the total fracture zone height was found to be at 141 m and the hydraulic connected fracture zone at 87.7 m above the top of the Pittsburgh seam. In addition to core drilling through the gob, FLAC3D modeling was also used to simulate the formation of fracture zone and the orientations of longwall-induced fractures. This study provides much-needed evidence on the fracture zone of Pittsburgh seam longwall gobs to help gas operators avoid potential hazards associated with drilling through highly fractured zones

Mar 2, 2022

By Prescott Greene

AVAILABLE MACHINES Machines discussed in this section include only rubber tire mounted kerf cutting machines of a self¬propelled electrically powered design. Such machines handle bars up to 4.6 m (15 ft) in length, cutting kerfs of from 115 to 191 mm (4.5 to 7.5 in.). The basic design concept of all machines currently in production is very similar. The chassis features dual driving wheels on the cutter-bar end, fixed directly to the main frame. The steering wheels on the outby end of the frame are articulated in some manner to keep all four wheels on the floor over uneven bottom. Machine power for tramming, and all other functions except powering the cutting chain, is furnished from a pump motor that drives the specific pump or pumps required by a given machine. The cutter chain is driven through a mechanical drive train from a separate electric motor having no duty other than driving the chain. The general arrangement of a cutting machine is shown in Fig. 1; two types of machines, with their specifications are shown in Figs. 2 through 5. A hydraulically powered cable normally is included to eliminate the need for manual cable handling and make this a one-man machine. A bug duster, though optional, is needed for most applications. The bug duster is an hydraulically driven scroll conveyor located directly behind the cutter chain drive sprocket. Its function is to move the cuttings away from the sprocket to prevent them from packing up in this area and consuming a lot of machine power to further pulverize them. Available machines vary from models 610 mm (24 in.) high that can cut horizontally only from 203 mm (8 in.) below ground line to 229 mm (9 in.) above, to machines 1143 mm (45 in.) high that can cut in any plane from 178 mm (7 in.) below the ground line to 3.7 m (12 ft) above it. Most currently manufactured machines fall in the 17 200 to 20 400 kg (38,000 to 45,000 lb) weight range, but can be dis¬assembled for underground installation where weight and size are a problem. Maximum teardown results in all pieces having a weight of 5400 kg (12,000 lb) or less and a size allowing passage through a 1.2 x 2.1-m (4x7-ft) opening. Further reduction in either size or weight of the parts becomes a serious problem. Machines currently being manufactured are avail¬able for use with power supplies of 250 v dc; 500 v dc; 440, 550, or 950 v ac (60 Hz). Also available are machines for use on 415, 500, and 950 v 50 Hz. De¬signs to allow operation on other voltages of either 50 or 60 Hz can be made available without any serious problems. As of September 1977, a typical medium-seam ma¬chine without the extra options needed for unusual conditions, but fully equipped to operate, was selling for about $185,000. CAPABILITIES Materials That Can Be Cut The problem of deciding before a machine is put on the job whether it can work effectively is an old one that has never been completely solved and probably

Jan 1, 1982

By Hongsheng He, Xiaofang Lv, Jianfeng Wang

This paper provided an overview of characteristics of limonite ores as well as their influence on sintering performance. Evaluation experiments focusing on basic characteristics, granulation characteristics, and high temperature sintering characteristics had been conducted by using two types of limonite ores, then the principles of high effective utilization technology of limonite ores were discussed, and the sintering pot tests were conducted. Limonite ores possessed low total iron content, high combined water content, high SiO2 content, large average particle size, low adhering particles proportion, high porosity, high water absorption rate, short water absorbing time, poor granulation ability, high melt formation ability, low melt fluidity ability, low melt penetration ability, high melt absorption ability, low bonding phase strength, and high forming ability of SFCA. By taking the technical measures of ore-proportioning optimization, increasing the proportion of burntlime and segmentation granulation, the usage of limonite ores could reach 50% in sintering.

Aug 27, 2021

By M. D. Ballain, V. C. Storhok, B. Pesic, J. C. Sever

Northwest Alloys, a wholly owned subsidiary of Alcoa, produces magnesium from dolomite by reduction with ferrosilicon and aluminum. This process produces alkaline by-products in quantities that allow their consideration for use as commercial by-products. Two such products are dicalcium silicate slag, Di-Cal, and magnesium oxide condensate, MgO. The alkaline properties of these materials offer acid neutralizing capability comparable to the traditionally used lime, therefore, warranting a study for their use in applications where the neutralization of acidic waters or process solutions is required, such as treatment of mine waters. In this ongoing study, three mine waters (Bunker HillMine, Berkeley Pit, and Blackbird Mine) were selected for treatment with Di-Cal and MgO. Lime was used as the background control. The solid precipitates were subsequently contacted with pure water at four different pH conditions for stability testing of prepared metal precipitates (expanded TCLP). It was found that neutralization with Di-Cal results in precipitates which are of equivalent to superior stability than those from lime treatment.

Jan 1, 1999

By Sandeep Kumar Asarapalli, Sunil Kumar Bisoyi, Bhatu Kumar Pal

Spontaneous heating of coal is one of the major concerns in the coal mining industry. Hundreds of millions of tons of coal are lost each year because of spontaneous heating. If necessary arrangements are made, many fires due to spontaneous heating may be avoided. Therefore, protective measures have become essential to prevent coal from spontaneous combustion. A large amount of coal reserve can be saved by the assessment, suppression, and prediction of spontaneous heating of coal, which also helps in betterment and efficient coal production. The use of chemical retardants can act as inhibitors for the liability of coal toward spontaneous heating by increasing its ignition temperature, thereby, increasing its incubation period. The coal-chemical mixture can be used for whitewashing the exposed coal in galleries as it creates a layer between coal and oxygen in the atmosphere, delaying the oxidation process and ultimately inhibiting the spontaneous heating liability of coal. This work examines the effect of chemicals such as sodium chloride, calcium carbonate, potassium iodide, sodium nitrate, and potassium chloride on the spontaneous heating of a coal sample. Thereby, it suggests a better chemical for inhibiting the liability of coal toward spontaneous heating. The experimentation involves flammability temperature (FT), crossing point temperature (CPT), and differential thermal analysis (DTA). The ignition and oxidation temperatures were found from the above experimental methods for Lingaraj open-cast coal mine samples, with and without adding chemicals. The results are cross-checked and verified through DTA. Correlation analysis was carried out among the results obtained from CPT, DTA, and FT, and better chemical retardants that effectively inhibit coal’s tendency toward spontaneous heating were suggested.

Dec 23, 2023

By J. Wagner, P. Eger, G. Melchert

In 1991, LTV Steel Mining decided to close an open-pit taconite mine in northeastern Minnesota using a passive-treatment approach consisting of limiting infiltration into the stockpiles and wetland treatment to remove metals. More than 50 Aft (55 million st) of sulfide-containing waste had been stockpiled adjacent to the mine during its 30 years of operation. Drainage from the stockpiles contained elevated levels of copper, nickel, cobalt and zinc. Nickel is the major trace metal in the drainages. Before the closure, the annual median concentrations ranged from 1.5 to 50 mg/L. Copper, cobalt and zinc are also present but they are generally less than 5% of the nickel values. Median pH levels range from 5 to 7.5, but most of the stockpile drainages have pH levels greater than 6.5. Based on the chemical composition of each stockpile, a cover material was selected. The higher the potential that a stockpile had to produce acid drainage, the lower the permeability of the capping material required Covers ranged from overburden soil removed at the mine to a flexible plastic liner. Predictions of the reduction in infiltration ranged from 40% for the native soil to more than 90% for the plastic liner. Five constructed wetlands have been installed since 1992. They have removed 60% to 90% of the nickel in the drainages. Total capital costs for all the infiltration reduction and wetlands exceeded $6.5 million, but maintenance costs are less than 1 % of those for an active treatment plant. Because mine-drainage problems can continue for more than 100 years, the lower annual operating costs should pay for the construction of the wetland-treatment systems within seven years.

Jan 1, 2000

By B. R. Utz

The goal of the DOE Coal Preparation Program is to provide industry with the scientific and engineering knowledge base to produce economically competitive and environmentally acceptable clean coal products for both existing and new markets. The DOE/PETC in-house program continues to conduct fundamental, exploratory, and applied research in the areas of physical, chemical, and microbial coal beneficiation to assist in meeting these goals and objectives. The Coal Preparation Division now has a new Coal Preparation Process Research Facility that allows continuous bench-scale testing of emerging coal cleaning technologies and ancillary coal preparation equipment at feed rates up to 1,250 kilograms (1.25 tons) per hour. Bench-scale and laboratory-scale research projects at PETC cover areas such as 1) the use of micronized-magnetite for fine-coal, 2) heavy-media cycloning, 3) fine coal reconstitution, 4) development and testing of coal preparation process flowsheet simulators, 5) dry coal beneficiation using electrostatic methods, 6) tracer methods to determine the efficiency of density-based separations, 7) selective oxidation of organic sulfur, and 8) microbial removal of pyrite and organic sulfur from coal. This paper will discuss several of these research areas.

Jan 1, 1993

By J. Hanna

The University of Alabama Mineral Resources Institute (MRI) has developed a unique process for selective fatty acid flotation of carbonate gangue from sedimentary apatites (francolite) in the pH range of 4-6 without collector conditioning of the pulp. The process, which does not require an apatite depressant, was modified to benepciate a high- MgO siliceous phosphate matrix from south Florida. The modified process includes two flotation stages, one for car- bonate removal and the other for phosphate recovery from the siliceous gangue. The selective flotation separation of the carbonate and phosphate from siliceous constituents of the matrix at various pH levels and collector dosages are discussed. In the carbonate flotation stage, about 70% of the MgO was rejected in the froth. The phosphate flotation stage produced concentrates analyzing about 31% P2O5 0.7% ? 5 MgO, and 4% insol. The overall P2O5 recovery In the two stages was about 85%

Jan 1, 1991

By S. Mason

Many organizations are realizing that continual improvement in health and safety relies on addressing the potential for various forms of human error. Of these, violations are often the most frequent form associated with accidents. These occur when an individual, or individuals, deliberately contravenes established and known safety rules. They have been associated with up to 90% of accidents and incidents in some industries and yet rarely receive the systematic attention they deserve in the promotion of safety. This paper presents underlying motives which cause violations. These can vary significantly from mine to mine and from job to job. Managers need some measure of attitudes to determine the underlying motives behind violations if they are to determine effective strategies for promoting safe behaviour. Questionnaires form the starting point to address attitudes and the motives behind rule violations. The choice of the most suitable questionnaire, however, will vary from organization to organization. Guidelines on the choice of questionnaire are offered.

Jan 1, 1998

By Thien Sok, Yaojun Lu, Craig Gilbert, Jeremy Scott

Feedwells play a pivotal role in gravity thickeners, governing flow distribution, feed dilution, and flocculation condition during solid–liquid separation. This study presents an optimized design and digital prototyping framework for FLSmidth’s E-volute and E-Duc Feedwell systems, integrating advanced computational fluid dynamics (CFD) with quantitative criteria introduced at SME2024. Building on established FLS technologies, a series of novel configurations were developed and systematically assessed under full-scale and site-specific conditions. CFD provided quantitative insight into flow distribution, feed dilution, and flocculation efficiency, enabling iterative refinement of design parameters. The optimized feedwell demonstrated superior hydraulic performance, enhanced mixing, and improved flocculation outcomes. Beyond the specific design advances, the work highlights CFD as an effective and economical tool for digital prototyping, facilitating early identification of design limitations, reducing dependence on physical trials, and accelerating innovation. The methodology underscores the value of simulation-driven design in advancing feedwell performance and improving thickener technology.

Feb 22, 2026

By R. Scheffel, R. Washnock, G. Zarate

"The second survey of global copper leaching operations has been completed, the data published in 1998 has been updated. A survey questionnaire was sent to 40 identified copper leach operations around the world including those leach properties still in operation that responded to the 1998 survey. This paper lists the results of 26 operations that responded to the survey. Selected information from the survey is represented in graphical form. INTRODUCTION Copper leaching was first performed by truck dumping huge monolithic stockpiles of ore and flooding the surface with leach solution or lixiviant with little understanding to the parameters that support optimum recovery of the metal. Heap leaching has evolved into a controlled process whereby a complex low grade ore is stacked in shallow lifts (under 10 m in most cases). The ore is usually crushed and agglomerated, conveyor stacked on an engineered containment system (leach pad) and irrigated in a controlled manner. The lixiviant chemistry is designed to extract the optimum amount of metal from the ore. At first glance, heap leaching appears to be simple in nature. In fact, it is a very complex process. A plethora of technologies such as material handling, environmental control, analytical techniques, solution chemistry, hydrology and many others contribute to the design and operation of a heap leach. Heap leaching requires an inter-disciplinary approach between geologists, mining engineers and metallurgists. Many operational factors affect heap leaching. The process must address climatic factors, flexible operation, quality control before and after leaching, physical characteristics of the ore, geology, mineralogy, reagent consumption, solution application rate and methods (wobblers or emitters), particle size, and favorable conditions for bacterial growth and survival. Predicting, troubleshooting, and optimization of leach recovery is a significant challenge when considering the number of variables involved and their interactions The survey updates many of these key operating parameters to the current state of the art. It should provide the reader an excellent benchmarking summary of these factors on a site-by-site basis."

Jan 1, 2016

By P. W. Johnson, H. Fan, S. B. Patton, T. Novak, R. L. Sanford

A computer model is presented that quantitatively uses the relationship between the interactive and dynamic processes of methane drainage, mining, and ventilation. The model includes simulation of the coalbed methane reservoir for prediction of gas-emission rates under the influence of degasification wells and longwall mining, ventilation network-generation and ventilation simulation. As mining progresses step-wise through the coalbed-methane reservoir, the ventilation network is created and subsequently simulated, iteratively determining fan requirements to safely reduce methane concentrations. The model can be used to quantitatively study the effectiveness of methane degasitication on the ventilation system in a longwall panel.

Jan 1, 1995

By William H. Lehr

In recent years, we have witnessed many innovations in the equipment used in handling bulk materials. Not too long ago, any sizeable stockpile of coal or iron ore was attended by one or more material handling bridges. More recently, large stockpiles have been built with mobile equipment of' the earth moving type with bulldozers and front end Loaders being utilized in reclaiming operations. The most recent stocking and reclaiming device is the rotary bucket wheel machine. The early bucket wheel machines built in the United States were developed for the strip mining of coal. We understand that the first American machine was built in the Midwest in 1944. This type of unit was developed in an effort to reduce the cost of removing overburden and to provide satisfactory spoil disposal. As the available coal reserves under shallow cover were exhausted, the cost of removing the deeper overburden with conventional equipment became too great for these operations to continue profitably. The first machine has now been followed by six or seven additional units, the largest of which can handle material at a rate of more than 7000 cubic yards per hour.

Jan 1, 1965

By C. Heckman, M. S. Moats, A. Luyima, W. Cui

"Nucleation and growth of copper on 316L stainless steel from synthetic acidified copper sulfate was studied in the absence and presence of chloride ions and/or organic additives – HydroStar® 4208, DXG-F7® and Cyquest® N-900 – using a potentiostatic technique. The current–time data obtained at 0.16V versus the SHE were analyzed using nucleation and growth models. Scanning electron microscope (SEM) images of deposits produced at 300 A/m2 show that the addition of 20 mg/L chloride ions increased the size and reduced the number of copper nuclei. Potentiostatic current–time data from the electrolyte without organic additives, and confirmed by SEM images, indicate progressive nucleation with two-dimensional growth under diffusion control. None of the organic additives studied at a concentration of 2.5 mg/L with 20 mg/L chloride changed the nucleation and growth mechanism, but the additives increased the number and reduced the size of copper nuclei, leading to more uniform coverage of the stainless steel substrate.IntroductionElectrowinning of copper is an important process in the manufacture of high-purity copper metal. Approximately 20 percent of the world’s refined copper is produced from acidified copper sulfate solutions by electrowinning (Schlesinger, Sole and Davenport, 2011). In many plants, copper is electrodeposited on AISI 316L stainless steel substrates for a period of 6-7 days, after which the copper is stripped from the blanks. Even though the deposition time for a commercial copper electrowinning circuit is around one week, it is critically important to control the nucleation, growth and nature of the initial deposit (Sun and O’Keefe, 1992).Deposit morphology and structure are influenced by the real current density at the electrode surface. The real current density across the cathode surface is made uniform by proper design of the electrowinning cell and electrodes and careful operational practice. Even with good design and control, some current maldistribution occurs. The outcome of severe current maldistribution is poor deposits that affect product quality and/or increase energy consumption. To combat current maldistribution and create a larger operating window in terms of current density, temperature and copper concentration, small amounts of organic smoothing agents – traditionally, guar products – are added to copper electrowinning electrolytes. Moreover, these additives inhibit the growth of copper nodules and lead to improved deposit quality by producing bright, smooth and dense cathodes.Recently, the use of polysaccharides, such as HydroStar 4208 and DXG-F7, and polyacrylamides, such as Cyquest N-900, has been reported in commercial electrowinning tankhouses as replacements for guar (Ashford, Clayton and Sandoval, 2012; Robinson et al., 2013; Sandoval, Morales and Bernu, 2010). However, little information has been published on the effect of these new organic additives, especially regarding the nucleation and growth mechanisms of copper electrodeposits in their presence."

Jan 1, 2016

By R. Adsero

The volume of data produced by operating mines has increased substantially over the last 10 years. However, the volume of data and analytical capability has been negatively correlated to equipment productivity for at least the last seven years. In simple terms, as the volume of data has increased equipment performance has declined. Table (2010) tells us that ?The calamity of the information age is that the toxicity of data increases much faster than its benefits?. More data does not guarantee improving productivity; but more data is also not the cause of declining productivity. Similarly, when equipment performance does start to improve, (it must ? there really is no option if mines want to remain competitive), it will not be the data nor analytics which causes it; it will be the people using the resources at their disposal; including the data. Data and analytics can help if the toxicity of the data can be managed. The simplest form of business improvement using data is benchmarking. The objective of benchmarking is to understand and evaluate the current position of a process in relation to ?best practice? and to identify areas and means of performance improvement. The application of benchmarking involves four key steps: (1) Analyze and understand in detail existing processes; (2) Analyze and understand the processes of others; (3) Compare your own performance with that of the others analyzed; and (4) Design and implement the changes necessary to close the performance gap(s). There are however, many in the mining industries who have shunned equipment benchmarking because they believe that, ?every mine is a pilot?. In other words, the differences between mine operations make comparisons between them of little value. This paper will present a valid approach to benchmarking equipment performance and reliability, accounting for the differences and similarities between operations, producing a result which can be used to add value to mines around the world.

Feb 23, 2014

By Elizabeth Anne Semon

The marketability of a large volume bulk material is significantly effected by transportation costs. Hence, it is essential for anyone that deals with minerals or mineral wastes to be able to reliably estimate bulk transport costs. The three types of bulk overland transportation modes that will be discussed are truck, railroad, and pipeline. Contract and private carriage are the two types of truck transport generally suitable for movement of bulk commodities. Contract carriers are those transportation firms that service a limited number of shippers and geographic points, and carry a restricted number of commodities. Private carriage consists of control over drivers and equipment by the shipper, ownership or lease of the transport equipment, and shipment of commodities related to the primary business of the shipper.1 A combination of private and contract carriage may also be used. Depending on the size and regularity of the shipment, rail offers single car, multiple car, or unit train service to move bulk minerals. Both long and short distance pipeline transportation has been shown economically and technically feasible for many different solids such as, mine and quarry products, coal, chemicals, copper concentrates, phosphate rock, and sewage sludge. 2

Jan 1, 1973

By Palmer King

The increased emphasis on environmental protection, together with the exorbitant costs, or in many urban areas the complete unavailability of surface space, has resulted in a burgeoning demand for greater use of underground space. More and more, those considering new or expanded facilities are looking toward the possibility of utilizing underground space for communications installations, for transportation of people, industrial products, water, sewage and energy, and for industrial installations. Happily, this growing demand for use of underground space is accompanied by fast forward strides looking toward more efficient underground excavation techniques. The tunnel boring machine is already here and where ground conditions are suitable for its use it can greatly reduce the cost of underground excavations, savings of one-third or more often being realized. Research is underway involving excavation by use of laser beams, jetting, vibrations, improvement of tunnel boring machines to make possible the excavation of harder rock, and other advanced techniques. The Engineering Foundation estimated in 1973 that tunneling costs can be reduced as much as 30 percent by rapid excavation methods which are expected to be developed through ongoing research programs in the next few years. Your American Society of Civil Engineers reported in 1973 that $60 billion per year, or 15 percent of the gross national product, could be saved if facilities required to support life were located in the subsurface. Studies looking toward improved contracting practices are going on under the sponsorship of the National Academy of Sciences, and Mr. Al Mathews who is heading this program will address you during this session on the status of this project. I myself am a member of Mr. Mathews' study group and, considering the human element involved, it is too early to make predictions as to what can be accomplished in the way of savings in costs of

Jan 1, 1974

By H. M. Breza

Utilization of Bucket Wheel Excavators and Overland Conveyor Systems to remove overburden provides increased productivity and flexibility to a surface mining operation. The utilization of such a system at the Texasgulf Inc. Aurora, North Carolina Mine has significantly improved the overall productivity of the mining operation. System flexibility is evidenced by adaptation to operation requirements such as mining area moves, movement of excavated overburden to designated sites, selective handling of overburden, spoil placement contouring, and providing an environmentally sound and safe operation. System productivity is evidenced by actual case studies relating to overall production, excavation rates, and cost effectiveness.

Jan 1, 1993

By D. M. S. Bhatia

Five sulfide minerals from the Magiwnt mine, southeast Missouri were analyzed for 31 trace elements in over 300 samples by laser microprobe spectrographic analysis of polished sections. The concentration of several trace elements shows a pattern of progressive variation with depth (space) and variation with different paragenetic stages (time) of each mineral. Factor analysis of the geochemical data shows sympathetic correlation both in space and in time of Bi, Cd, Ge, and Sn in galena and sphalerite, and Ni and Co in sphalerite and marcasite.

Jan 1, 1979